Floor covering comprising recycled PVC and method for the manufacture of such covering

Abstract

The present invention relates to a multilayer polyvinyl chloride (PVC) floor covering intermediate sheet and a multilayer PVC floor covering comprises such a PVC floor covering intermediate sheet. The PVC floor covering intermediate sheet and the PVC floor covering are typically characterized in that they comprise recycled PVC material. The present invention also relates to methods for manufacturing such a multilayer PVC floor covering intermediate sheet and multilayer PVC floor covering, and to an apparatus for manufacturing a multilayer PVC floor covering intermediate sheet or a multilayer PVC floor covering.

Description

[0001] FLOOR COVERING COMPRISING RECYCLED PVC AND METHOD FOR THE MANUFACTURE OF SUCH COVERING

[0002] TECHNICAL FIELD

[0003] The present invention relates to the field of floor coverings and floor covering intermediate sheets, such as floor covering and floor covering intermediate sheet. In particular, the present invention relates to a multilayer floor covering intermediate sheet comprising recycled polyvinyl chloride (PVC) and a multilayer floor covering comprising said intermediate sheet. Also methods for the manufacture of a multilayer floor covering intermediate sheet comprising recycled polyvinyl chloride (PVC) are disclosed.

[0004] BACKGROUND

[0005] Cushion floor coverings are a well-known and popular material today. A wide variety of designs, easy installation, long lifespan, and affordable price make them attractive in the market. Cushion floor coverings are typically made of different layers of PVC based compounds with different material properties per layer.

[0006] However, in a circular and sustainable economy, there is a need to include more recycled materials. With known coating technologies, it is not technically feasible to obtain cushion vinyl floor coverings that have a considerable amount of recycled content (>10%) and still comply to quality standards and are made in a cost-effective way. With known calendering or doublebelt press technologies, it is not financially feasible to obtain cushion vinyl floor coverings that have a considerable amount of recycled content (>10%) and still comply to quality standards. Although the current calendering and double-belt technologies offer a wider flexibility for processing raw materials due to melting the compound at high temperatures (>150°C), the products today lack sufficient percentage of recycled content. One of the main reasons is the insecure nature and supply of the recycled content available. Further, also foaming of the product during a calendering or double-belt process in order to obtain the typical cushion vinyl nature has its limits, which is more emphasized when using recycled content. Technical issues may arise from residual blowing agent and foamed particles, which in compact calendering needs to be removed prior to the extruder, e.g. by using special Banbury mixers or de-gassing on the extruder, or chemical deactivation.

[0007] It is therefore an objective of the current invention to provide a solution for one or more of the above shortcomings. It is an objective to provide a sustainable multilayer PVC floor covering intermediate sheet comprising recycled PVC or a multilayer PVC floor covering comprising recycled PVC. It is an objective to provide a sustainable multilayer PVC floor covering intermediate sheet comprising recycled PVC or a multilayer PVC floor covering comprising recycled PVC with optimal mechanical properties, insulation, and / or acoustic properties. It is an objective to provide a sustainable multilayer PVC floor covering intermediate sheet comprising recycled PVC or a multilayer PVC floor covering comprising recycled PVC with a reduced environmental impact. It is an objective to provide a sustainable multilayer PVC floor covering intermediate sheet comprising recycled PVC or a multilayer PVC floor covering comprising recycled PVC that contributes to a circular economy.

[0008] It is an objective to provide a sustainable method for manufacturing a multilayer PVC floor covering intermediate sheet or a multilayer PVC floor covering comprising recycled PVC, preferably working towards a circular economy, thereby reducing the environmental impact. It is an objective to provide a sustainable multilayer PVC floor covering intermediate sheet comprising recycled PVC ora multilayer PVC floor covering comprising recycled PVC, wherein the production process reduces virgin fossil-based resource consumption. It is an objective to provide a method for manufacturing a multilayer PVC floor covering intermediate sheet comprising recycled PVC or a multilayer PVC floor covering comprising recycled PVC that is simplified, and that lowers energy and production costs. It is an objective to provide a method for manufacturing a multilayer floor covering intermediate sheet comprising recycled PVC or a multilayer PVC floor covering comprising recycled PVC that allows for increased recycled content. It is an objective to provide such methods that also result in a multilayer PVC floor covering intermediate sheet comprising recycled PVC or a multilayer PVC floor covering comprising recycled PVC with optimal mechanical properties, insulation, and / or acoustic properties.

[0009] SUMMARY OF THE INVENTION

[0010] The invention has for its object to remedy or to reduce at least one of the drawbacks of the prior art, or at least provide a useful alternative to prior art. The object is achieved through features, which are specified in the description below and in the claims that follow.

[0011] The invention is defined by the independent patent claims. The dependent claims define advantageous embodiments of the invention.

[0012] The inventors have developed a multilayer PVC floor covering intermediate sheet comprising recycled PVC material and a method of manufacturing such intermediate sheet. Further developed is a multilayer PVC floor covering comprising said floor covering intermediate sheet comprising recycled PVC material. Specifically, the multilayer PVC floor covering intermediate sheet of the invention or manufactured by a method according to the invention comprises a first layer comprising recycled PVC material and a second layer comprising glass fibres and a binder. Optionally, the multilayer PVC floor covering intermediate sheet also comprises a third layer comprising recycled PVC material. The second layer is preferably characterized by having a free volume of at least 200.10-6m3 / m2, preferably at least 255.10-6m3 / m2. Alternatively or additionally, the second layer is preferably characterized by having an air permeability of at least 3000 l / m2.s, preferably at least 5000 l / m2.s, preferably at least 6000 l / m2.s, as measured according to DIN EN ISO 9237.

[0013] The inventors have developed a PVC floor covering intermediate sheet that comprises a significantly increased amount of recycled PVC content as compared to other floor covering sheets. As such, a PVC floor covering intermediate sheet and a PVC floor covering are provided that contribute to a circular economy, thereby reducing the environmental impact of these products.

[0014] Finally, the inventors developed a PVC floor covering intermediate sheet and PVC floor covering as disclosed herein that demonstrates improved optimal mechanical properties, as well as improved acoustic properties, and / or improved insulation. More specifically, the PVC floor covering intermediate sheet comprising recycled PVC as disclosed herein provides a lower indentation, an increased tensile strength, an increased delamination, and / or a lower curling, as compared to a floor covering intermediate sheet that comprises only virgin PVC.

[0015] In a first aspect, the present invention thus relates to a PVC floor covering intermediate sheet comprising a first layer and a second layer, wherein the first layer comprises recycled PVC material and the second layer comprises glass fibres, said intermediate sheet preferably being characterized in that the second layer has a free volume of at least 200.1 O'6m3 / m2, preferably at least 255.1 O'6m3 / m2.

[0016] Also provided is a PVC floor covering intermediate sheet comprising a first layer and a second layer, wherein the first layer comprises recycled PVC material and the second layer comprises glass fibres and a binder, said intermediate sheet preferably being characterized in that the second layer has a free volume of at least 200.1 O'6m3 / m2, preferably at least 255.1 O'6m3 / m2.

[0017] In some preferred embodiments, the second layer of the intermediate sheet disclosed herein has a free volume of at most 500.1 O'6m3 / m2. In some preferred embodiments, the second layer has a free volume of at least 200.10'6m3 / m2and at most 500.10'6m3 / m2, for example preferably at least 255. 10'6m3 / m2and at most 500.10'6m3 / m2.

[0018] In some embodiments, the PVC floor covering intermediate sheet as disclosed herein comprises a first layer, a second layer, and a third layer, wherein the first layer and the third layer each comprise recycled PVC material and the second layer comprises glass fibres and optionally a binder, said intermediate sheet preferably being characterized in that the second layer has a free volume of at least 200. 10-6m3 / m2, preferably at least 255. 10-6m3 / m2. Also provided is a PVC floor covering intermediate sheet comprising a first layer and a second layer, wherein the first layer comprises recycled PVC material and the second layer comprises glass fibres, said intermediate sheet being characterized in that the second layer has an air permeability of at least 3000 l / m2.s, preferably at least 5000 l / m2.s, preferably at least 6000 l / m2.s, for example as measured according to DIN EN ISO 9237.

[0019] Also provided is a PVC floor covering intermediate sheet comprising a first layer and a second layer, wherein the first layer comprises recycled PVC material and the second layer comprises glass fibres and a binder, said intermediate sheet being characterized in that the second layer has an air permeability of at least 3000 l / m2.s, preferably at least 5000 l / m2.s, preferably at least 6000 l / m2.s, for example as measured according to DIN EN ISO 9237.

[0020] In some embodiments, the second layer of the intermediate sheet disclosed herein has an air permeability of at most 12000 l / m2.s. In some embodiments, the second layer has an air permeability of at least 3000 l / m2.s, preferably at least 5000 l / m2.s, preferably at least 6000 l / m2.s, and at most 12000 l / m2.s.

[0021] In some embodiments, the PVC floor covering intermediate sheet as disclosed herein comprises a first layer, a second layer, and a third layer, wherein the first layer and the third layer each comprise recycled PVC material and the second layer comprises glass fibres and optionally a binder, said intermediate sheet being characterized in that the second layer has an air permeability of at least 3000 l / m2.s, preferably at least 5000 l / m2.s, preferably at least 6000 l / m2.s, for example as measured according to DIN EN ISO 9237.

[0022] In some embodiments, the PVC floor covering intermediate sheet as disclosed herein comprises a first layer, a second layer, and a third layer, wherein the first layer and the third layer each comprise recycled PVC material and the second layer comprises glass fibres and a binder, said intermediate sheet being characterized in that the second layer has an air permeability of at least 3000 l / m2.s, preferably at least 5000 l / m2.s, preferably at least 6000 l / m2.s, for example as measured according to DIN EN ISO 9237.

[0023] Also provided is a PVC floor covering intermediate sheet comprising a first layer and a second layer, wherein the first layer comprises recycled PVC material and the second layer comprises glass fibres, said intermediate sheet being characterized in that the second layer has a free volume of at least 200.1 O'6m3 / m2, preferably at least 255.1 O'5m3 / m2, and an air permeability of at least 3000 l / m2.s, preferably at least 5000 l / m2.s, preferably at least 6000 l / m2.s, for example as measured according to DIN EN ISO 9237.

[0024] Also provided is a PVC floor covering intermediate sheet comprising a first layer and a second layer, wherein the first layer comprises recycled PVC material and the second layer comprises glass fibres and a binder, said intermediate sheet being characterized in that the second layer has a free volume of at least 200.10-6m3 / m2, preferably at least 255.10-6m3 / m2, and an air permeability of at least 3000 l / m2.s, preferably at least 5000 l / m2.s, preferably at least 6000 l / m2.s, for example as measured according to DIN EN ISO 9237.

[0025] In some preferred embodiments, the second layer of the intermediate sheet disclosed herein has a free volume of at most 500.1 O'6m3 / m2. In some preferred embodiments, the second layer has a free volume of at least 200.1 O'6m3 / m2, preferably at least 255.1 O'6m3 / m2, and at most 500.1 O'6m3 / m2. In some embodiments, the second layer has an air permeability of at most 12000 l / m2.s. In some embodiment, the second layer has an air permeability of at least 3000 l / m2.s, preferably at least 5000 l / m2.s, preferably at least 6000 l / m2.s, and at most 12000 l / m2.s. In some preferred embodiments, the second layer has a free volume of at least 200.10'6m3 / m2, preferably at least 255.1 O'6m3 / m2, and at most 500.1 O'6m3 / m2and an air permeability of at least 3000 l / m2.s, preferably at least 5000 l / m2.s, preferably at least 6000 l / m2.s, and at most 12000 l / m2.s.

[0026] In some embodiments, the PVC floor covering intermediate sheet as disclosed herein comprises a first layer, a second layer, and a third layer, wherein the first layer and the third layer each comprise recycled PVC material and the second layer comprises glass fibres and optionally a binder, said intermediate sheet being characterized in that the second layer has a free volume of at least 200.1 O'6m3 / m2, preferably at least 255.1 O'6m3 / m2, and at most 500.1 O'6m3 / m2and an air permeability of at least 3000 l / m2.s, preferably at least 5000 l / m2.s, preferably at least 6000 l / m2.s, and at most 12000 l / m2.s, for example as measured according to DIN EN ISO 9237.

[0027] In some embodiments, the PVC floor covering intermediate sheet as disclosed herein comprises a first layer, a second layer, and a third layer, wherein the first layer and the third layer each comprise recycled PVC material and the second layer comprises glass fibres and a binder, said intermediate sheet being characterized in that the second layer has a free volume of at least 200.1 O'6m3 / m2, preferably at least 255.1 O'6m3 / m2, and at most 500.1 O'6m3 / m2and an air permeability of at least 3000 l / m2.s, preferably at least 5000 l / m2.s, preferably at least 6000 l / m2.s, and at most 12000 l / m2.s, for example as measured according to DIN EN ISO 9237.

[0028] In some embodiments, the glass fibres in the intermediate sheet as disclosed herein have a length of at least 4 mm to at most 20 mm. In some preferred embodiments, the glass fibres have a length of at least 6 mm and at most 18 mm, for examples a length of about 8 mm or about 10 mm. In some embodiments, the glass fibres in the intermediate sheet as disclosed herein have a diameter of at least 4 m to at most 20 pm; preferably at least 6 pm to at most 18 pm, for example a diameter of about 12 pm.

[0029] In some embodiments, the first layer, and optionally the third layer, of the PVC floor covering intermediate sheet as disclosed herein each independently comprise at least 50% recycled PVC material, based on the total weight of the first layer, and optionally the third layer respectively; preferably at least 60%, more preferably at least 70%; even more preferably at least 80% recycled PVC material, such as for example 90%, or 95%, or 98% or even 100% recycled PVC material, based on the total weight of the first layer, and optionally the third layer respectively.

[0030] In some embodiments, the recycled PVC material comprises at least 10% recycled PVC, based on the total weight of the recycled PVC material. In some embodiments, the recycled PVC material comprises at least 20% recycled PVC, based on the total weight of the recycled PVC material. In some embodiments, the recycled PVC material comprises at least 30% recycled PVC, preferably at least 40% recycled PVC, for example at least 50% recycled PVC. In some embodiments, the recycled PVC material comprises at least 60% recycled PVC, preferably at least 70% recycled PVC, more preferably at least 80% recycled PVC or at least 90% recycled PVC, such as for example 95%, 98%, or even 100% recycled PVC, based on the total weight of the recycled PVC material.

[0031] In some embodiments, the floor covering intermediate sheet comprises at least 50% recycled PVC material, based on the total weight of the floor covering intermediate sheet, preferably at least 60% recycled PVC material, preferably at least 70% recycled PVC material, more preferably at least 80% recycled PVC material, even more preferably at least 90% PVC material, for example at least 95% recycled PVC material or at least 98% recycled PVC material, based on the total weight of the floor covering intermediate sheet.

[0032] In some embodiments, the second layer is located on top of the first layer of the PVC floor covering intermediate sheet. In some embodiments, the third layer is located on top of the second layer of the PVC floor covering intermediate sheet. In some preferred embodiments, the second layer is located in between the first layer and the third layer.

[0033] In some embodiments, the second layer of the PVC floor intermediate sheet as disclosed herein comprises glass fibres and a binder. In some preferred embodiments, the second layer is impregnated with a binder. In some embodiments, the second layer comprises at most 40% by weight binder, based on the total weight of the second layer, preferably at least 10% by weight binder to at most 30% by weight binder, for example about 20% by weight binder. In some embodiments, the glass fibres in the second layer of the intermediate sheet are comprised in a glass fibre fabric, web, or fleece, such as for example, a non-woven glass fibre fabric, web, or fleece.

[0034] A further aspect provides a multilayer PVC floor covering comprising the PVC floor covering intermediate sheet according to aspects disclosed herein, and (preferred) embodiments thereof.

[0035] In some embodiments, the multilayer PVC floor covering comprises a backing layer. In some embodiments, the PVC floor covering thus comprises a PVC floor covering intermediate sheet as disclosed herein and a backing layer. In some preferred embodiments, the PVC floor covering intermediate sheet is located on top of the backing layer, in particular wherein the first layer of the intermediate sheet is in contact with the backing layer.

[0036] In some embodiments, the multilayer PVC floor covering does not comprise a backing layer.

[0037] In some embodiments, the multilayer PVC floor covering comprises a decorative layer; preferably wherein the decorative layer is located on top of the intermediate sheet.

[0038] In some embodiments, the decorative layer comprises a decor layer. In some embodiments, the decorative layer comprises a decor layer and a print layer.

[0039] In some embodiments, the multilayer PVC floor covering comprises a print layer and a decor layer, together forming a decorative layer; preferably wherein the decor layer is located on top of the intermediate sheet, and the print layer is located on top of the decor layer.

[0040] In some embodiments, the multilayer PVC floor covering comprises a wear layer. In some embodiments, said wear layer is located on top of the decorative layer. In some embodiments, the wear layer is located on top of the print layer.

[0041] In some embodiments, the multilayer PVC floor covering comprises at least 50% recycled PVC material, based on the total weight of the PVC floor covering, preferably at least 60% recycled PVC material, preferably at least 70% recycled PVC material, for example at least 80% recycled PVC material, based on the total weight of the PVC floor covering.

[0042] A further aspect provides a method for manufacturing a multilayer PVC floor covering intermediate sheet according to any of the embodiments disclosed herein. Said method preferably comprises that step of: (a) providing a glass fibre layer comprising glass fibres and a binder, wherein the free volume in the glass fibre layer is at least 255.1 O'6m3 / m2; (b) providing a first film comprising recycled PVC material; (c) laminating the first film of step (b) to the glass fibre layer of step (a), thereby forming a PVC floor covering intermediate sheet comprising a first layer formed by the first film and a second layer formed by the glass fibre layer.

[0043] In some embodiments, step (b) of the method further comprises providing a second film comprising recycled PVC material and step (c) further comprises laminating the second film to the glass fibre layer on the opposite side to the first film, thereby forming a PVC covering intermediate sheet comprising a first layer formed by the first film, a second layer formed by the glass fibre layer, and a third layer formed by the second film.

[0044] In some embodiments, step (b) of the method comprises the steps of: providing a first batch of recycled PVC material; optionally mixing the first batch of recycled PVC material with one or more first components, to form a first mixture; melting the first batch of recycled PVC material or the first mixture to form a first film; adhering the first film to one side of a glass fibre layer, thereby forming a multilayer structure comprising a first layer formed by the first film, and a second layer formed by the glass fibre layer, thereby forming a multilayer PVC floor covering intermediate sheet according to any of the embodiments disclosed herein. The one or more first components may be selected from a foaming agent, a stabilizer, TiO2, a plasticizer, a filler, or a combination thereof.

[0045] In some embodiments, step (b) of said method comprises the steps of: providing a first batch of recycled PVC material; optionally mixing the first batch of recycled PVC material with one or more first components, to form a first mixture; melting the first batch of recycled PVC material or the first mixture to form a first film; laminating the first film to one side of a glass fibre layer, thereby forming a multilayer structure comprising a first layer formed by the first film, and a second layer formed by the glass fibre layer, thereby forming a PVC floor covering intermediate sheet according to any of the embodiments disclosed herein. The one or more first components may be selected from a foaming agent, a stabilizer, TiC>2, a plasticizer, a filler, or a combination thereof.

[0046] Another aspect provides a method for manufacturing a multilayer PVC floor covering intermediate sheet according to any of the embodiments disclosed herein. Said method preferably comprises the steps of: providing a first batch of recycled PVC material and a second batch of recycled PVC material; optionally mixing the first batch of recycled PVC material with one or more first components to form a first mixture; optionally mixing the second batch of recycled PVC material with one or more second components to form a second mixture; melting the first batch of recycled PVC material or the first mixture to form a first film; melting the second batch of recycled PVC material or the second mixture to form a second film; adhering the first film to one side of a glass fibre layer and adhering the second film to the other side of the glass fibre layer, thereby forming a multilayer structure comprising a first layer formed by the first film, a second layer formed by the glass fibre layer and a third layer formed by the second film; thereby forming a multilayer PVC floor covering intermediate sheet according to any of the embodiments disclosed herein. The one or more first and / or second components may be each independently selected from a foaming agent, a stabilizer, TiC>2, a plasticizer, a filler, or a combination thereof.

[0047] In some embodiments, the method preferably comprises the steps of: providing a first batch of recycled PVC material and a second batch of recycled PVC material; optionally mixing the first batch of recycled PVC material with one or more first components to form a first mixture; optionally mixing the second batch of recycled PVC material with one or more second components to form a second mixture; melting the first batch of recycled PVC material or the first mixture to form a first film; melting the second batch of recycled PVC material or the second mixture to form a second film; laminating the first film to one side of a glass fibre layer and laminating the second film to the other side of the glass fibre layer, thereby forming a multilayer structure comprising a first layer formed by the first film, a second layer formed by the glass fibre layer and a third layer formed by the second film; thereby forming a PVC floor covering intermediate sheet according to any of the embodiments disclosed herein. The one or more first and / or second components may be each independently selected from a foaming agent, a stabilizer, TiC»2, a plasticizer, a filler, or a combination thereof.

[0048] Also provided is a PVC floor covering intermediate sheet as manufactured according to any of the methods disclosed herein.

[0049] Another aspect of the invention relates to an apparatus or production line for manufacturing a multilayer PVC floor covering intermediate sheet or a multilayer PVC floor covering wherein the apparatus or production line is configured for performing a method according to an aspect of the invention, and (preferred) embodiments thereof.

[0050] DETAILED DESCRIPTION OF THE FIGURES

[0051] In the following is described examples of preferred embodiments illustrated in the accompanying drawings, wherein:

[0052] FIG. 1 illustrates a PVC floor covering intermediate sheet (10) according to an embodiment of the invention. The intermediate sheet (10) comprises a first layer (1) and a second layer (2).

[0053] FIG. 2 illustrates a PVC floor covering (20) according to an embodiment of the invention. The floor covering (20) comprises a PVC floor covering intermediate sheet (10) with a first (1) and a second (2) as disclosed herein, and a backing layer (21). FIG. 3 illustrates a PVC floor covering (20) according to an embodiment of the invention. The floor covering (20) comprises a PVC floor covering intermediate sheet (10) with a first (1) and a second (2) layer as disclosed herein, and a decorative layer (22).

[0054] FIG. 4 illustrates a PVC floor covering (20) according to an embodiment of the invention. The floor covering (20) comprises a PVC floor covering intermediate sheet (10) with a first (1) and a second (2) layer as disclosed herein, and a decor layer (23) and a print layer (24), together forming the decorative layer (22).

[0055] FIG. 5 illustrates a PVC floor covering (20) according to an embodiment of the invention. The floor covering (20) comprises a PVC floor covering intermediate sheet (10) with a first (1) and a second (2) layer as disclosed herein, and a decorative layer (22) and a wear layer (25).

[0056] FIG. 6 illustrates a PVC floor covering (20) according to an embodiment of the invention. The floor covering (20) comprises a backing layer (21), a PVC floor covering intermediate sheet (10) with a first (1) and a second (2) layer as disclosed herein, and a decorative layer (22) and a wear layer (25).

[0057] FIG. 7 illustrates a PVC floor covering intermediate sheet (10) according to an embodiment of the invention. The intermediate sheet (10) comprises a first layer (1), a second layer (2) and a third layer (3).

[0058] FIG. 8 shows a microscopic image of a PVC floor covering intermediate sheet (10) according to an embodiment of the invention. The intermediate sheet (10) comprises a first layer (1) and a third layer (3), each comprising recycled PVC material, and both layers are laminated onto a second layer (2), which is a glass fibre web.

[0059] FIG. 9 illustrates a PVC floor covering (20) according to an embodiment of the invention. The floor covering (20) comprises a PVC floor covering intermediate sheet (10) with a first (1), a second (2) and a third layer (3) as disclosed herein, and a backing layer (21).

[0060] FIG. 10 illustrates a PVC floor covering (20) according to an embodiment of the invention. The floor covering (20) comprises a PVC floor covering intermediate sheet (10) with a first (1), a second (2) and a third layer (3) as disclosed herein, and a decorative layer (22).

[0061] FIG. 11 illustrates a PVC floor covering (20) according to an embodiment of the invention. The floor covering (20) comprises a PVC floor covering intermediate sheet (10) with a first (1), a second (2) and a third layer (3) as disclosed herein, and a decor layer (23) and a print layer (24), together forming the decorative layer (22).

[0062] FIG. 12 illustrates a PVC floor covering (20) according to an embodiment of the invention. The floor covering (20) comprises a PVC floor covering intermediate sheet (10) with a first (1), a second (2) and a third layer (3) as disclosed herein, and a decorative layer (22) and a wear layer (25).

[0063] FIG. 13 illustrates a PVC floor covering (20) according to an embodiment of the invention. The floor covering (20) comprises a backing layer (21), a PVC floor covering intermediate sheet (10) with a first (1), a second (2) and a third layer (3) as disclosed herein, and a decorative layer (22) and a wear layer (25).

[0064] FIG. 14 illustrates a flow chart of the different steps in a method to manufacture a PVC floor covering intermediate sheet (10) according to an embodiment of the invention.

[0065] Any positional indications refer to the position shown in the figures. In the figures, same or corresponding elements are indicated by same reference numerals. For clarity reasons, some elements may in some of the figures be without reference numerals. A person skilled in the art will understand that the figures are just principal drawings. The relative proportions of individual elements may also be distorted.

[0066] DETAILED DESCRIPTION OF THE INVENTION

[0067] When describing the invention, the terms used are to be construed in accordance with the following definitions, unless the context dictates otherwise.

[0068] As used herein, the singular forms "a”, "an", and "the" include both singular and plural referents unless the context clearly dictates otherwise. By way of example, "a resin" means one resin or more than one resin.

[0069] The terms "comprising", "comprises" and "comprised of" as used herein are synonymous with "including", "includes" or "containing", "contains", and are inclusive or open-ended and do not exclude additional, non-recited members, elements, or method steps. It will be appreciated that the terms "comprising", "comprises" and "comprised of" as used herein comprise the terms "consisting of", "consists" and "consists of".

[0070] The recitation of numerical ranges by endpoints includes all integer numbers and, where appropriate, fractions subsumed within that range (e.g., 1 to 5 can include 1, 2, 3, 4 when referring to, for example, a number of elements, and can also include 1.5, 2, 2.75 and 3.80, when referring to, for example, measurements). The recitation of end points also includes the end point values themselves (e.g., from 1.0 to 5.0 includes both 1.0 and 5.0). Any numerical range recited herein is intended to include all sub-ranges subsumed therein.

[0071] All references cited in the present specification are hereby incorporated by reference in their entirety. In particular, the teachings of all references herein specifically referred to are incorporated by reference. Reference throughout this specification to “one embodiment” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrases “in one embodiment” or “in an embodiment” in various places throughout this specification are not necessarily all referring to the same embodiment, but may. Furthermore, the particular features, structures or characteristics may be combined in any suitable manner, as would be apparent to a person skilled in the art from this disclosure, in one or more embodiments. Furthermore, while some embodiments described herein include some, but not other features included in other embodiments, combinations of features of different embodiments are meant to be within the scope of the invention, and form different embodiments, as would be understood by those in the art.

[0072] Unless defined otherwise, percentages are percentages by weight, based on the total weight of the composition or article referred to. For example, a composition comprising 50.0% PVC, refers to 50.0 wt% PVC based on the total weight of the composition. On the other hand, a floor covering comprising 50.0% PVC, refers to 50.0 wt% PVC based on the total weight of the floor covering, including all layers.

[0073] The terms described above, and others used in the specification are well understood to those skilled in the art.

[0074] Preferred statements (features) and embodiments, resins, articles, methods, and uses of this invention are set herein below. Each statement and embodiment of the invention so defined may be combined with any other statement and / or embodiment unless clearly indicated to the contrary. In particular, any feature indicated as being preferred or advantageous may be combined with any other feature or features or statements indicated as being preferred or advantageous.

[0075] The independent and dependent claims set out particular and preferred features of the invention. Features from the dependent claims may be combined with features of the independent or other dependent claims as appropriate.

[0076] The present invention will now be further described. In the following passages, different aspects of the invention are defined in more detail. Each aspect so defined may be combined with any other aspect or aspects unless clearly indicated to the contrary. In particular, any feature indicated as being preferred or advantageous may be combined with any other feature or features indicated as being preferred or advantageous.

[0077] In a first aspect, the present invention relates to a PVC floor covering intermediate sheet comprising a first layer and a second layer, wherein the first layer comprises recycled PVC material and the second layer comprises glass fibres, and wherein the second layer of the intermediate sheet preferably has a free volume of at least 200.10-6m3 / m2, preferably at least 255.10 ® m3 / m2.

[0078] Also provided is a PVC floor covering intermediate sheet comprising a first layer and a second layer, wherein the first layer comprises recycled PVC material and the second layer comprises glass fibres and a binder, and wherein the second layer of the intermediate sheet has a free volume of at least 200.1 O'6m3 / m2, preferably at least 255.1 O'6m3 / m2.

[0079] In some embodiments, the second layer of the intermediate sheet is further characterized by an air permeability of at least 3000 l / m2.s, preferably at least 5000 l / m2.s, preferably at least 6000 l / m2.s, for example as measured according to DIN EN ISO 9237.

[0080] In some embodiments, a PVC floor covering intermediate sheet is provided comprising a first layer, a second layer, and a third layer, wherein the first layer and the third layer each comprise recycled PVC material and the second layer comprises glass fibres, and wherein the second layer of the intermediate sheet has a free volume at least 200.1 O'6m3 / m2, preferably at least

[0081] 255.1 O'6m3 / m2. In some embodiments, a PVC floor covering intermediate sheet is provided comprising a first layer, a second layer, and a third layer, wherein the first layer and the third layer each comprise recycled PVC material and the second layer comprises glass fibres and a binder, and wherein the second layer of the intermediate sheet has a free volume at least

[0082] 200.1 O'6m3 / m2, preferably at least 255.1 O'6m3 / m2. In some embodiments, the second layer of the intermediate sheet is further characterized by an air permeability of at least 3000 l / m2.s, preferably at least 5000 l / m2.s, preferably at least 6000 l / m2.s, for example as measured according to DIN EN ISO 9237.

[0083] Also provided is a PVC floor covering intermediate sheet comprising a first layer and a second layer, wherein the first layer comprises recycled PVC material and the second layer comprises glass fibres, and wherein the second layer of the intermediate sheet has an air permeability of at least 3000 l / m2.s, preferably at least 5000 l / m2.s, preferably at least 6000 l / m2.s, for example as measured according to DIN EN ISO 9237.

[0084] Also provided is a PVC floor covering intermediate sheet comprising a first layer and a second layer, wherein the first layer comprises recycled PVC material and the second layer comprises glass fibres and a binder, and wherein the second layer of the intermediate sheet has an air permeability of at least 3000 l / m2.s, preferably at least 5000 l / m2.s, preferably at least 6000 l / m2.s, for example as measured according to DIN EN ISO 9237.

[0085] In some embodiments, a PVC floor covering intermediate sheet is provided comprising a first layer, a second layer, and a third layer, wherein the first layer and the third layer each comprise recycled PVC material and the second layer comprises glass fibres, and wherein the second layer of the intermediate sheet has an air permeability of at least 3000 l / m2.s, preferably at least 5000 l / m2.s, preferably at least 6000 l / m2.s, for example as measured according to DIN EN ISO 9237.

[0086] In some embodiments, a PVC floor covering intermediate sheet is provided comprising a first layer, a second layer, and a third layer, wherein the first layer and the third layer each comprise recycled PVC material and the second layer comprises glass fibres and a binder, and wherein the second layer of the intermediate sheet has an air permeability of at least 3000 l / m2.s, preferably at least 5000 l / m2.s, preferably at least 6000 l / m2.s, for example as measured according to DIN EN ISO 9237.

[0087] Also provided herein is a method for the manufacture of a PVC floor covering intermediate sheet (10), wherein the method comprises the steps of:

[0088] (a) providing a glass fibre layer comprising glass fibres and a binder, wherein the free volume in the glass fibre layer is at least 255.1 O'6m3 / m2;

[0089] (b) providing a first film comprising recycled PVC material;

[0090] (c) laminating the first film of step (b) to the glass fibre layer of step (a), thereby forming a PVC floor covering intermediate sheet comprising a first layer formed by the first film and a second layer formed by the glass fibre layer.

[0091] In some embodiments, step (b) of said method may further comprise providing a second film comprising recycled PVC material and step (c) of said method may further comprise laminating the second film to the glass fibre layer on the opposite side of the first film, thereby forming a PVC floor covering intermediate sheet comprising a first layer formed by the first film, a second layer formed by the glass fibre layer, and a third layer formed by the second film.

[0092] In some embodiments, step (b) of said method comprises providing a first batch of recycled PVC material, and melting the first batch of recycled PVC material to form the first film.

[0093] In some embodiments, step (b) of said method further comprises providing a second batch of recycled PVC material, and melting the second batch of recycled PVC material to form the second film.

[0094] As used herein, the term “PVC floor covering” may also be referred to as “a floor covering comprising PVC”, or “sheet vinyl” or “flexible vinyl”.

[0095] As used herein, the term “PVC floor covering intermediate sheet” may also be referred to as “an intermediate sheet” and may refer to a part of the PVC floor covering as disclosed herein. In some embodiments, the second layer of the PVC floor covering intermediate sheet as disclosed has a free volume of at least 200.10-6m3 / m2, preferably at least 250. 10-6m3 / m2, preferably at least 255.1 O’6m3 / m2, preferably at least 260.1 O’6m3 / m2, preferably at least

[0096] 265.1 O'6m3 / m2, preferably at least 270.1 O’6m3 / m2, preferably at least 275.1 O’6m3 / m2. In some preferred embodiments, the second layer of the PVC floor covering intermediate sheet has a free volume of at least 250.10’6m3 / m2. In some further preferred embodiments, the second layer of the PVC floor covering intermediate sheet has a free volume of at least 255.1 O'6m3 / m2, more preferably at least 260. 10’6m3 / m2, such as for example at least 262.10’6m3 / m2, at least 263.10'6m3 / m2, or at least 264.10'6m3 / m2.

[0097] In some embodiments, the second layer of the PVC floor covering intermediate sheet as disclosed has a free volume of at most 500.10’5m3 / m2. In some preferred embodiments, the second layer of the PVC floor covering intermediate sheet has a free volume of at most 480.1 O’6m3 / m2. In some further preferred embodiments, the second layer of the PVC floor covering intermediate sheet has a free volume of at most 470.1 O’6m3 / m2, such as for example at most

[0098] 460.1 O’6m3 / m2, at most 455.1 O’6m3 / m2, or at most 450.1 O’6m3 / m2.

[0099] In some embodiments, the second layer of the PVC floor covering intermediate sheet as disclosed has a free volume of at least 200.1 O’6m3 / m2, preferably at least 255.1 O’6m3 / m2, and at most 500.10’6m3 / m2. In some preferred embodiments, the second layer of the PVC floor covering intermediate sheet has a free volume of at least 250.10’6m3 / m2and at most 500.10’6m3 / m2. In some embodiments, the second layer of the PVC floor covering intermediate sheet has a free volume of at least 255.1 O’6m3 / m2and at most 500.1 O’6m3 / m2. In some embodiments, the second layer of the PVC floor covering intermediate sheet has a free volume of at least 255.10’6m3 / m2and at most 480.10’6m3 / m2. In some further preferred embodiments, the second layer of the PVC floor covering intermediate sheet has a free volume of at least 260. 10’6m3 / m2, such as for example at least 262.1 O’6m3 / m2, at least 263.10’6m3 / m2, or at least 264.1 O’6m3 / m2, and a free volume of at most 470.1 O’5m3 / m2, such as for example at most 460.1 O’6m3 / m2, at most 455.1 O’6m3 / m2, or at most 450.1 O’6m3 / m2.

[0100] In some embodiments, the second layer of the glass fibre layer as provided to form the second layer of the intermediate sheet as disclosed has a free volume of at least 200.1 O’6m3 / m2, preferably at least 250.1 O’6m3 / m2, preferably at least 255.1 O’6m3 / m2, preferably at least

[0101] 260.1 O’6m3 / m2, preferably at least 265.1 O’6m3 / m2, preferably at least 270.1 O’6m3 / m2, preferably at least 275.10sm3 / m2. In some preferred embodiments, the glass fibre layer as provided has a free volume of at least 250.1 O’6m3 / m2. In some further preferred embodiments, the glass fibre layer as provided has a free volume of at least 255.1 O’6m3 / m2, more preferably at least 260. 10'6m3 / m2, such as for example at least 262. 10'6m3 / m2, at least 263.10'6m3 / m2, or at least 264.1 O'6m3 / m2.

[0102] In some embodiments, the glass fibre layer as provided sheet as disclosed has a free volume of at most 500.1 O'6m3 / m2. In some preferred embodiments, the glass fibre layer as provided has a free volume of at most 480.10'6m3 / m2. 1 n some further preferred embodiments, the glass fibre layer as provided has a free volume of at most 470.1 O'6m3 / m2, such as for example at most 460.1 O'6m3 / m2, at most 455.1 O'6m3 / m2, or at most 450.1 O'6m3 / m2.

[0103] In some embodiments, the glass fibre layer as provided has a free volume of at least 200.10'6m3 / m2, preferably at least 255.1 O'6m3 / m2, and at most 500.1 O'6m3 / m2. In some preferred embodiments, the glass fibre layer as provided has a free volume of at least 250.1 O'6m3 / m2and at most 500.1 O'6m3 / m2. In some embodiments, the glass fibre layer as provided has a free volume of at least 255.1 O'6m3 / m2and at most 500.1 O'6m3 / m2. In some embodiments, the glass fibre layer as provided has a free volume of at least 255.10sm3 / m2and at most 480.10'6m3 / m2. In some further preferred embodiments, the glass fibre layer as provided has a free volume of at least 260.1 O'6m3 / m2, such as for example at least 262.1 O'6m3 / m2, at least 263.10'6m3 / m2, or at least 264.1 O'6m3 / m2, and a free volume of at most 470.1 O'6m3 / m2, such as for example at most 460.1 O'6m3 / m2, at most 455.1 O'6m3 / m2, or at most 450.1 O'6m3 / m2.

[0104] As used herein the free volume of the second layer or of the glass fibre layer refers to the degree of interstitial space between the components present in said second layer or glass fibre layer. In other words, the free volume of the second layer, which is a glass fibre layer, or of the glass fibre layer as provided in step (a) of the method for the manufacture of a PVC floor covering intermediate sheet, refers to the space or voids within glass fibre material of said second layer or of said glass fibre layer.

[0105] The free volume of a layer as used herein is preferably calculated using the following formula (I): free volume (m3 / m2) Formula (I) can alternatively be presented as follows: m3

[0106] Free volume m2

[0107] As used in Formula I, thickness (in m) refers to the thickness of the second layer, which is the glass fibre layer, or to the thickness of the glass fibre layer as provided in step (a) of the method for the manufacture of a PVC floor covering intermediate sheet. In some embodiments, the thickness of the second layer of the intermediate sheet is measured according to EN ISO 9073-2. In some embodiments, the thickness of the glass fibre layer as provided is measured according to EN ISO 9073-2; preferably at a pressure of 2 kPa. For example, measurement of the thickness of the second layer or the glass fibre layer as provided is performed by applying a pressure 2 kPa on the layer.

[0108] As used in Formula I , the area weight (in kg / m2) refers the weight (in kg) per area of the second layer or the glass fibre layer as provide, in m2. In some embodiments, the area weight is measured according to EN ISO 29073-1.

[0109] Further, also the weight% of the binder present in the intermediate sheet or glass fibre layer and the binder density (kg / m3) are taken into account, as well as the density of the glass fibres (glass density; kg / m3).

[0110] In some embodiments, the free volume of the second layer of the intermediate sheet can be determined after separation of the second layer from the first layer and optionally the third layer of the intermediate sheet. Several methods are available and known to the skilled person to isolate a glass fibre layer from a multilayer structure comprising PVC. For example, the glass fibre layer can be isolated using tetrahydrofuran, thereby dissolving the PVC layers, i.e. the first layer and optionally the third layer in the intermediate sheet. The use of tetra hydrofuran allows the glass fibre layer to be separated from the other PVC comprising layers. If needed, the glass fibre layer can be rinsed in a fresh batch of tetrahydrofuran or ethanol to remove any residual polymer and solvent. For example, the glass fibre layer can be isolated by rinsing the intermediate sheet in tetra hydrofuran at a temperature of 20.0°C to 40.0°C for 1 h to 6h. The duration of the treatment depends on the thickness of the intermediate sheet. Optionally, and in a next step, the glass fibre layer obtained after dissolving the PVC comprising layers, can be rinsed in fresh tetra hydrofuran or ethanol to remove any residual polymer and solvent.

[0111] In some embodiments, the thickness, area weight and free volume of the second layer in the intermediate sheet is the same as the free volume of the second layer as provided to manufacture the intermediate sheet. In some embodiments, and as also shown in the experimental data (Table 4), the thickness, area weight and free volume of the second layer in the intermediate sheet are similar to the thickness, area weight and free volume of the second layer as provided to manufacture the intermediate sheet, with a maximum difference of 10.0%; preferably of 8.0%; more preferably of 7.0%.

[0112] In some embodiments, the second layer of the PVC floor covering intermediate sheet as disclosed has an air permeability of at least 3000 l / m2.s, preferably at least 4000 l / m2.s, preferably at least 5000 l / m2.s, preferably at least 5500 l / m2.s, preferably at least 6000 l / m2.s, preferably at least 6500 l / m2.s, preferably at least 7000 l / m2.s, preferably at least 7500 l / m2.s, preferably at least 8000 l / m2.s, preferably at least 8500 l / m2.s, for example as measured according to DIN EN ISO 9237. In some preferred embodiments, the second layer of the PVC floor covering intermediate sheet has an air permeability of at least 4000 l / m2.s, preferably at least 4500 l / m2.s, more preferably at least 5000 l / m2.s. In some further preferred embodiments, the second layer of the PVC floor covering intermediate sheet has an air permeability of at least 6000 l / m2.s, such as for example at least 6200 l / m2.s.

[0113] In some embodiments, the second layer of the PVC floor covering intermediate sheet as disclosed has an air permeability of at most 12000 l / m2.s as measured according to DIN EN ISO 9237. In some preferred embodiments, the second layer of the PVC floor covering intermediate sheet has an air permeability of at most 11000 l / m2.s, for example as measured according to DIN EN ISO 9237. In some further preferred embodiments, the second layer of the PVC floor covering intermediate sheet has an air permeability of at most 10000 l / m2.s, such as for example at most 9500 l / m2.s, or at most 9300 l / m2.s.

[0114] In some embodiments, the second layer of the PVC floor covering intermediate sheet as disclosed has an air permeability of at least 3000 l / m2.s, preferably at least 5000 l / m2.s, preferably at least 6000 l / m2.s, and at most 12000 l / m2.s, for example as measured according to DIN EN ISO 9237. In some preferred embodiments, the second layer of the PVC floor covering intermediate sheet has an air permeability of at least 4000 l / m2.s and at most 11000 l / m2.s. In some further preferred embodiments, the second layer of the PVC floor covering intermediate sheet has an air permeability of at least 4500 l / m2.s, such as for example at least 4800 l / m2. s , and an air permeability of at most 10000 l / m2.s, such as for example at most 9500 l / m2.s, or at most 9300 l / m2.s.

[0115] In some embodiments, the glass fibre layer as provided in step (a) of the method for the manufacture of a PVC floor covering intermediate sheet as disclosed has an air permeability of at least 3000 l / m2.s, preferably at least 4000 l / m2.s, preferably at least 5000 l / m2.s, preferably at least 5500 l / m2.s, preferably at least 6000 l / m2.s, preferably at least 6500 l / m2.s, preferably at least 7000 l / m2.s, preferably at least 7500 l / m2.s, preferably at least 8000 l / m2.s, preferably at least 8500 l / m2.s, for example as measured according to DIN EN ISO 9237. In some preferred embodiments, the glass fibre layer as provided has an air permeability of at least 4000 l / m2.s, preferably at least 4500 l / m2.s, more preferably at least 5000 l / m2.s. In some further preferred embodiments, the glass fibre layer as provided an air permeability of at least 6000 l / m2.s, such as for example at least 6200 l / m2.s.

[0116] In some embodiments, the glass fibre layer as provided has an air permeability of at most 12000 l / m2.s as measured according to DIN EN ISO 9237. In some preferred embodiments, the glass fibre layer as provided has an air permeability of at most 11000 l / m2.s, for example as measured according to DIN EN ISO 9237. In some further preferred embodiments, the glass fibre layer as provided has an air permeability of at most 10000 l / m2.s, such as for example at most 9500 l / m2.s, or at most 9300 l / m2.s.

[0117] In some embodiments, the glass fibre layer as provided has an air permeability of at least 3000 l / m2.s, preferably at least 5000 l / m2.s, preferably at least 6000 l / m2.s, and at most 12000 l / m2.s, for example as measured according to DIN EN ISO 9237. In some preferred embodiments, the glass fibre layer has an air permeability of at least 4000 l / m2.s and at most 11000 l / m2.s. In some further preferred embodiments, the glass fibre layer has an air permeability of at least 4500 l / m2.s, such as for example at least 4800 l / m2.s, and an air permeability of at most 10000 l / m2.s, such as for example at most 9500 l / m2.s, or at most 9300 l / m2.s.

[0118] As used herein, the air permeability of the second layer as used herein refers to the permeability of the second layer to air. Further as used herein, the air permeability of the glass fibre layer as provided refers to the permeability of the glass fibre layer as provided to air; preferably to the air permeability of the glass fibre as provided and prior to assembly of said glass fibre layer into the PVC floor covering intermediate sheet.

[0119] The air permeability is preferably measured according to DIN EN ISO 9237. The surface of the measurement head was 20 cm2. The applied test pressure was 200 Pa. In some embodiments, the air permeability of the second layer of the intermediate sheet can be determined after separation of the second layer from the first layer and optionally the third layer of the intermediate sheet. Several methods are available and known to the skilled person to isolate a glass fibre layer from a multilayer structure comprising PVC. For example, the glass fibre layer can be isolated using tetrahydrofuran, thereby dissolving the PVC layers, i.e. the first layer and optionally the third layer in the intermediate sheet. The use of tetra hydrofuran allows the glass fibre layer to be separated from the other PVC comprising layers. If needed, the glass fibre layer can be rinsed in a fresh batch of tetrahydrofuran or ethanol to remove any residual polymer and solvent. For example, the glass fibre layer can be isolated by rinsing the intermediate sheet in tetra hydrofuran at a temperature of 20.0°C to 40.0°C for 1 h to 6h. The duration of the treatment depends on the thickness of the intermediate sheet. Optionally, and in a next step, the glass fibre layer obtained after dissolving the PVC comprising layers, can be rinsed in fresh tetra hydrofuran or ethanol to remove any residual polymer and solvent.

[0120] In some embodiments, the glass fibres in the second layer of the PVC floor covering intermediate sheet as disclosed herein or in the glass fibre layer as provided in step (a) of the method for the manufacture of the PVC floor covering intermediate sheet, are comprised in a glass fibre fabric, a web, or a fleece, such as for example, a non-woven glass fibre fabric, a non-woven glass fibre web or a non-woven glass fibre fleece.

[0121] The PVC floor covering intermediate sheet as disclosed herein comprises a second layer comprising glass fibres. Alternatively, the PVC floor covering intermediate sheet as disclosed herein comprises a second layer comprising glass fibres and a binder. In preferred embodiments, the PVC floor covering intermediate sheet as disclosed herein comprises a second layer comprising glass fibres and a binder.

[0122] The glass fibre layer as provided in step (a) of the method as disclosed herein comprises glass fibres. Alternatively, the glass fibre layer as provided in step (a) of the method as disclosed herein comprises glass fibres and a binder. In preferred embodiments, the glass fibre layer as disclosed herein comprises a second layer comprising glass fibres and a binder.

[0123] The glass fibre layer as used herein, or the second layer may act as a carrier or substrate material for the first and optionally the third layer of the intermediate sheet. The glass fibre layer or the second layer becomes a core layer of the product and may serve multiple main purposes: as a platform for the first and optionally the third layer; to prevent the whole product from heat shrinkage during the heating stage during production; and / or, to ensure dimensional stability of the final flooring product.

[0124] In some embodiments, the glass fibres in the glass fibre layer or in the intermediate sheet as disclosed herein have a length of at least 4 mm, preferably of at least 6 mm. In some embodiments, the glass fibres in the glass fibre layer and / or in the intermediate sheet as disclosed herein have a length of at most 20 mm, preferably at most 18 mm. In some embodiments, the glass fibres in the glass fibre layer and / or in the intermediate sheet as disclosed herein have a length of at least 4 mm to at most 20 mm. In some preferred embodiments, the glass fibres have a length of at least 6 mm and at most 18 mm, preferably of at least 6 mm and at most 12 mm, for example a length of about 8 mm or of about 10 mm.

[0125] In some embodiments, the glass fibres in the glass fibre layer and / or in the intermediate sheet as disclosed herein have a diameter of at least 4 pm; preferably at least 6 pm. In some embodiments, the glass fibres in the glass fibre layer and / or in the intermediate sheet as disclosed herein have a diameter of at most 20 pm; preferably at most 18 pm. In some embodiments, the glass fibres in the glass fibre layer and / or in the intermediate sheet as disclosed herein have a diameter of at least 4 pm to at most 20 pm; preferably at least 6 pm to at most 18 pm, for example a diameter of about 12 pm.

[0126] In some embodiments, the glass fibres in the glass fibre layer and / or in the intermediate sheet as disclosed herein have a sizing applied to them.

[0127] In some embodiments, the PVC floor covering intermediate sheet comprises a binder, in particular, the second layer of the PVC floor covering intermediate sheet comprises a binder. In some further embodiments, the second layer is impregnated with the binder. In some embodiments, the second layer comprises at most 40% by weight binder, based on the total weight of the second layer, preferably at least 10% by weight binder to at most 30% by weight binder, for example about 20% by weight binder.

[0128] In some embodiments, the glass fibre layer as provided in step (a) of the method disclosed herein comprises a binder. In some further embodiments, the glass fibre layer is impregnated with the binder. In some embodiments, the glass fibre layer at most 40% by weight binder, based on the total weight of the second layer, preferably at least 10% by weight binder to at most 30% by weight binder, for example about 20% by weight binder.

[0129] In some embodiments, the binder can be a polymeric binder. In some embodiments, the binder can be a resin, preferably a resin selected from polyester resin, vinyl ester resin, phenolic resin, polyurethane resin, urea-formaldehyde resin, or a combination thereof. In some embodiments, the binder is urea-formaldehyde resin.

[0130] In some embodiments, the second layer comprises a continuous layer, such as a glass fibre webbing. In some embodiments, the second layer comprises a discontinuous layer, such as individually dispersed glass fibres, which are adhered to the first layer and optionally the third layer of the intermediate sheet.

[0131] In some embodiments, the second layer, preferably a continuous or dispersed glass fibre layer, has a weight of at least 5 g / m2to at most 100 g / m2, preferably at least 10 g / m2to at most 60 g / m2, preferably at least 20 g / m2to at most 40 g / m2, for example about 30 g / m2.

[0132] In some embodiments, the glass fibre layer as provided in step (a) of the method disclosed herein comprises a continuous layer, such as a glass fibre webbing. In some embodiments, the glass fibre layer comprises a discontinuous layer, such as individually dispersed glass fibres, which can become adhered to the first layer and optionally the third layer of the intermediate sheet.

[0133] In some embodiments, the glass fibre layer, preferably a continuous or dispersed glass fibre layer, has a weight of at least 5 g / m2to at most 100 g / m2, preferably at least 10 g / m2to at most 60 g / m2, preferably at least 20 g / m2to at most 40 g / m2, for example about 30 g / m2.

[0134] In some embodiments, the PVC floor covering intermediate sheet as disclosed herein comprises a first layer comprising recycled PVC material and a second layer comprising glass fibres and optionally a binder, wherein the second layer is located on top of the first layer.

[0135] In some embodiments, the second layer or the glass fibre layer has an upper surface and a lower surface, wherein the lower surface of the second layer or glass fibre layer is adhered to the first layer having an upper surface and a lower surface. In some preferred embodiments, the lower surface of the second layer is adhered to the upper surface of the first layer.

[0136] In some embodiments, the second layer or the glass fibre layer has an upper surface and a lower surface, wherein the lower surface of the second layer or glass fibre layer is applied to the first layer having an upper surface and a lower surface. In some preferred embodiments, the lower surface of the second layer is applied to the upper surface of the first layer. In some embodiments, the first layer and the second layer are laminated together.

[0137] In some embodiments, the PVC floor covering intermediate sheet as disclosed herein comprises a third layer comprising recycled PVC material. In some embodiments, the PVC floor covering intermediate sheet therefore comprises a first layer comprising recycled PVC material, a second layer comprising glass fibres and a third layer comprising recycled PVC material. In some preferred embodiments, the third layer is located on top of the second layer. In some preferred embodiments, the second layer of the PVC floor covering intermediate sheet is located on top of the first layer. In some preferred embodiments, the second layer of the PVC floor covering intermediate sheet is located in between the first layer and the third layer of said PVC floor covering intermediate sheet.

[0138] In some embodiments, the third layer has an upper surface and a lower surface, wherein the lower surface is adhered to the second layer or glass fibre layer having an upper surface and a lower surface, in particular wherein the lower surface of the third layer is adhered to the upper surface of the second layer or glass fibre layer. In some embodiments, the lower surface of the third layer is adhered to the upper surface of the second layer or glass fibre layer and the lower surface of the second layer or glass fibre layer is adhered to the upper surface of the first layer.

[0139] In some embodiments, the third layer has an upper surface and a lower surface, wherein the lower surface is applied to the second layer having an upper surface and a lower surface, in particular wherein the lower surface of the third layer is applied to the upper surface of the second layer. In some embodiments, the lower surface of the third layer is applied to the upper surface of the second layer and the lower surface of the second layer is adhered to the upper surface of the first layer. In some embodiments, the first layer, the second layer, and the third layer are laminated together to form the PVC floor covering intermediate sheet.

[0140] The PVC floor covering intermediate sheet is characterized by the presence of recycled PVC material, in particular by the presence of recycled PVC material in the first layer, and when a third layer is present, also in the third layer, of the intermediate sheet.

[0141] The first film and optionally the second film as provided in any of the methods disclosed herein are characterized by the presence of recycled PVC material.

[0142] As used herein, the terms “recycled” or “recycling” refer to the process or method of reclaiming, reprocessing, and reusing materials or products that have already been used or consumed or to materials or products that are obtained as post-industrial waste, thereby diverting them from disposal as waste. As used herein, the term “recycled PVC” refers to PVC that has undergone some recycling process to reclaim and reuse PVC material that has previously been used in other applications.

[0143] In some preferred embodiments, the recycled PVC material comprises at least 20% recycled PVC, based on the total weight of the recycled PVC material. In some preferred embodiments, the recycled PVC material comprises at least 30% recycled PVC, based on the total weight of the recycled PVC material, preferably at least 40%, at least 50%, or at least 60% recycled PVC, more preferably at least 70% recycled PVC, more preferably at least 80% recycled PVC, even more preferably at least 90% recycled PVC. For example, the recycled PVC material may comprise 60% recycled PVC, or even 70%, 80%, 90%, 95% or even 100% recycled PVC, based on the total weight of the recycled PVC material.

[0144] In some embodiments, the recycled PVC material comprises recycled PVC and one or more other compounds, such as fillers and / or plasticizers.

[0145] In some preferred embodiments, the multilayer PVC floor covering intermediate sheet comprises at least 50% recycled PVC material, based on the total weight of the multilayer PVC floor covering intermediate sheet, preferably at least 60% recycled PVC material, preferably at least 70% recycled PVC material, more preferably at least 80% recycled PVC material, even more preferably at least 90% recycled PVC material, such as for example 90%, or 95% or 98% or even 100% recycled PVC material. In some preferred embodiments, the multilayer PVC floor covering intermediate sheet comprises at least 50% total recycled content, based on the total weight of the multilayer PVC floor covering intermediate sheet, preferably at least 60% total recycled content, preferably at least 70% total recycled content, more preferably at least 80% total recycled content, even more preferably at least 90% total recycled content, such as for example 90%, or 95% or 98% or even 100% total recycled content.

[0146] For example, if the PVC floor covering intermediate sheet comprises a second layer of glass fibres and a first and third layer comprising recycled PVC material, the entire multilayer PVC floor covering intermediate sheet comprises a percentage of recycled PVC material calculated as follows: sum of the weight of recycled PVC material in the first layer and in the third layer, divided by the total weight of the multilayer PVC floor covering intermediate sheet.

[0147] In some embodiments, the first layer comprises at least 50% recycled PVC material, based on the total weight of the first layer, preferably at least 60% recycled PVC material, preferably at least 70% recycled PVC material, more preferably at least 80% recycled PVC material, even more preferably at least 90% recycled PVC material, such as for example at least 95% or at least 98% or even 100% recycled PVC material.

[0148] In some embodiments, the first film as provided in step (b) of the method for the manufacture of a PVC floor covering intermediate sheet as disclosed herein, comprises at least 50% recycled PVC material, based on the total weight of the first film, preferably at least 60% recycled PVC material, preferably at least 70% recycled PVC material, more preferably at least 80% recycled PVC material, even more preferably at least 90% recycled PVC material, such as for example at least 95% or at least 98% or even 100% recycled PVC material. In some embodiments, the third layer comprises at least 50% recycled PVC material, based on the total weight of the third layer, preferably at least 60% recycled PVC material, preferably at least 70% recycled PVC material, more preferably at least 80% recycled PVC material, even more preferably at least 90% recycled PVC material, such as for example at least 95% or at least 98% or even 100% recycled PVC material.

[0149] In some embodiments, the second film as provided in step (b) of the method for the manufacture of a PVC floor covering intermediate sheet as disclosed herein, comprises at least 50% recycled PVC material, based on the total weight of the second film, preferably at least 60% recycled PVC material, preferably at least 70% recycled PVC material, more preferably at least 80% recycled PVC material, even more preferably at least 90% recycled PVC material, such as for example at least 95% or at least 98% or even 100% recycled PVC material.

[0150] In some preferred embodiments, the first and third layer each comprise at least 50% recycled PVC material, based on the total weight of the first or third layer respectively, preferably at least 60% recycled PVC material, preferably at least 70% recycled PVC material, more preferably at least 80% recycled PVC material, even more preferably at least 90% recycled PVC material, such as for example at least 95% or at least 98% or even 100% recycled PVC material.

[0151] In some preferred embodiments, the first and / or third layer each comprise at least 50% total recycled content, based on the total weight of the first and / or third layer respectively, preferably at least 60% total recycled content, preferably at least 70% total recycled content, more preferably at least 80% total recycled content, even more preferably at least 90% total recycled content, such as for example at least 95% or at least 98% or even 100% total recycled content.

[0152] In some preferred embodiments, the first and second film as provided in step (b) of the method as disclosed herein each comprise at least 50% recycled PVC material, based on the total weight of the first or second film respectively, preferably at least 60% recycled PVC material, preferably at least 70% recycled PVC material, more preferably at least 80% recycled PVC material, even more preferably at least 90% recycled PVC material, such as for example at least 95% or at least 98% or even 100% recycled PVC material.

[0153] In some preferred embodiments, the first and / or second film each comprise at least 50% total recycled content, based on the total weight of the first and / or second film respectively, preferably at least 60% total recycled content, preferably at least 70% total recycled content, more preferably at least 80% total recycled content, even more preferably at least 90% total recycled content, such as for example at least 95% or at least 98% or even 100% total recycled content. The recycled PVC material as used herein may come from mechanical recycled PVC waste, such as from flooring, windows and / or cables. In preferred embodiments, the recycled PVC material may come from mechanical recycled PVC waste obtained from the production process of flooring products.

[0154] In some embodiments, the recycled PVC material is prepared at ambient temperature.

[0155] In some embodiments, the recycled PVC material is prepared by mechanical recycling, thereby generating the recycled PVC material as shredded material, as pellets or as powder. In some preferred embodiments, the recycled PVC material is in the form of a powder, preferably a powder with an average particle size between 10-1000 pm.

[0156] In some embodiments, the recycled PVC material is prepared by mechanical recycling, or by advanced recycling, such as chemical or physical recycling (for example solvent-assisted recycling). In some preferred embodiments, the recycled PVC material is prepared by mechanical recycling.

[0157] In some embodiments, the origin of the recycled PVC material is post-industrial waste, preconsumer waste (before / after installation), post-consumer waste, flooring waste, waste from cables or window profiles. In some preferred embodiments, the origin of the recycled PVC material is post-industrial waste, preferably post-industrial flooring waste.

[0158] In some embodiments, the PVC floor covering intermediate sheet further comprises one or more components, such as for example one or more components selected from foaming agent or blowing agent, a stabilizer, TiC>2, a plasticizer, a filler, or a combination thereof.

[0159] In some embodiments, the first layer, and if a third layer is present, also the third layer, of the PVC floor covering intermediate sheet may comprise a blowing agent. In some embodiments, the first layer of the PVC floor covering intermediate sheet comprises a first blowing agent. In some embodiments, the third layer of the PVC floor covering intermediate sheet comprises a second blowing agent. In some embodiments, the first layer of the PVC floor covering intermediate sheet comprises a first blowing agent and the third layer of the PVC floor covering intermediate sheet comprises a second blowing agent.

[0160] In some embodiments, the first film, and if a second film is provided, also the second film, as provided in step (b) of the method for the manufacture of a PVC floor covering intermediate sheet, may comprise a blowing agent. In some embodiments, the first film comprises a first blowing agent. In some embodiments, the second film comprises a second blowing agent. In some embodiments, the first film comprises a first blowing agent and the second film comprises a second blowing agent. As used herein, the terms “blowing agent” and “foaming agent” may be used interchangeably, and refer to a chemical substance or mixture that is capable of generating gas, typically carbon dioxide, nitrogen, or water vapor, within a polymer matrix or other material, resulting in the formation of a cellular structure. This cellular structure, also referred to as foam, reduces the density of the material and provides desirable properties such as thermal and acoustic insulation, cushioning, and impact resistance. The blowing agent is preferably activated by heat.

[0161] In some preferred embodiments, the blowing agent can be selected from the group comprising: azodicarbonamide (AZO), 4,4-oxy-bis(benzenesulfonylhydrazide) (OBSH), P- toluenesulfonyl-hydrazide (TSH), P-tolyenesulfonylsemicarbazide (PTSS), dinitrosopentamethylenetetramine (DNPT), sodium bicarbonate, 5-phenyltetrazole (PT), or any combinations thereof; preferably the first and / or second blowing agent is AZO.

[0162] The term “sheet” also comprises a tile or plank. Preferably the sheet is a thin sheet, preferably a flexible thin sheet. In some embodiments, the PVC floor covering intermediate sheet has a thickness of at least 0.20 mm; preferably at least 0.25 mm, more preferably at least 0.30 mm. In some embodiments, the PVC floor covering intermediate sheet has a thickness of at most 2.00 mm, preferably at most 1.80 mm, more preferably at most 1.50 mm. In some embodiments, the PVC floor covering intermediate sheet has a thickness of at least 0.30 mm and at most 2.00 mm, such as a thickness of at least 0.50 mm and at most 2.00 mm.

[0163] In some embodiments, the second layer, preferably a continuous or dispersed glass fibre layer, has a thickness of at least 0.05 mm to at most 1.50 mm, preferably at least 0.10 mm to at most 1.00 mm, preferably at least 0.10 mm to at most 0.80 mm, more preferably at least 0.25 mm to at most 0.80 mm, or at least 0.25 mm to at most 0.50 mm; for example about 0.50 mm.

[0164] In some embodiments, the first layer, and if present, the third layer, each independently have a thickness of at least 0.05 mm to at most 1.50 mm, preferably at least 0.10 mm to at most 1.00 mm, preferably at least 0.10 mm to at most 0.80 mm, for example about 0.50 mm.

[0165] Another aspect of the invention relates to a multilayer PVC floor covering comprising a PVC floor covering intermediate sheet according to any of the aspects and embodiments disclosed herein. In preferred embodiments, the multilayer PVC floor covering is a cushion vinyl floor covering.

[0166] The multilayer PVC floor covering of the present invention comprises a PVC floor covering intermediate sheet as disclosed herein. The multilayer PVC floor covering may further comprise a backing layer. In some preferred embodiments, the PVC floor covering intermediate sheet is located on top of the backing layer. In some embodiments, the first layer of the intermediate sheet is in contact with the backing layer. In some preferred embodiments, the lower surface of the first layer of the PVC floor covering intermediate sheet is adhered to the backing layer, in particular to the upper surface of the backing layer.

[0167] In some embodiments, the PVC floor covering of the present invention does not comprise a backing layer.

[0168] The term “backing layer”, “backing sheet”, or “backing film” refers to a layer that may be used as a backing. The backing layer is preferably not a calendered layer.

[0169] The backing layer may comprise an additional PVC based layer, optionally foamed. The floor covering may comprise a non-woven layer, such as a non-woven polyester layer, PVC based layer, polypropylene based layer, in addition to the backing layer. The backing layer may comprise additional sublayers as a back print.

[0170] In some embodiments, the multilayer PVC floor covering further comprises a needle felt layer. In some embodiments, the needle felt layer is adhered to the backing layer, preferably to the lower surface of the backing layer. The presence of the needle felt layer provides several advantages, such as improved acoustic properties and / or no or less need to use an adhesive for installation of the floor covering.

[0171] In some embodiments, the needle-felt layer is a non-woven polyester layer of any desired density and colour, known by those skilled in the art. As used herein, the term “non-woven” refers to a sheet of fibres, continuous filaments, or chopped yams of any nature or origin, that have been formed into a web by any means, and bonded together by any means.

[0172] In some embodiments, the multilayer PVC floor covering may thus comprise a PVC floor covering intermediate sheet according to any of the embodiments disclosed herein, a backing layer and a needle felt layer, wherein the backing layer is located on top of the needle felt layer and the intermediate sheet is located on top of the backing layer.

[0173] The multilayer PVC floor covering may further comprise a decorative layer. In some embodiments, the decorative layer is located on top of the PVC floor covering intermediate sheet. In some embodiments, the decorative layer is located on top of the second layer of the PVC floor covering intermediate sheet, more specific wherein the lower surface of the decorative layer is adhered to the upper surface of the second layer. In some embodiments when the PVC floor covering intermediate sheet comprises a third layer, the decorative layer is located on top of said third layer of the PVC floor covering intermediate sheet, more specifically wherein the lower surface of the decorative layer is adhered to the upper surface of the third layer of the PVC floor covering intermediate sheet. In some embodiments, the PVC floor covering may comprise a decorative layer, a PVC floor covering intermediate sheet as disclosed herein, and a backing layer.

[0174] In some embodiments, the decorative layer comprises a decor layer. In some embodiments, the decor layer may comprise a print pattern. In some embodiments, the decor layer is located on top of the PVC floor covering intermediate sheet.

[0175] In some embodiments, the decor layer is located on top of the second layer of the PVC floor covering intermediate sheet. In some embodiments, and when the decor layer is located on top of the second layer comprising glass fibre an additional layer may be applied between the second layer and the decor layer. Said additional layer may comprise PVC or PVC and one or more plasticizers. In some embodiments, said additional layer may be applied by impregnation on the second layer.

[0176] In some embodiments, and when a third layer is present, the decor layer is located on top of the third layer of the PVC floor covering intermediate sheet.

[0177] In some embodiments, the decorative layer comprises a decor layer and a print layer. In some preferred embodiments, the print layer is located on top of the decor layer.

[0178] In some embodiments, the multilayer PVC floor covering comprises a print layer or print pattern and a decor layer, together forming the decorative layer. In some embodiments, the print layer or the print pattern is printed to the decor layer. The print layer or printing pattern can for example be applied to the decorative layer by rotogravure, digital printing, etc.

[0179] As used herein, the terms “decor layer”, “decor sheet”, or “decor film” refers to a layer to which a print layer or print pattern can be applied. The decor layer is typically white. In some embodiments, the decor layer comprises PVC and one or more plasticizers. In some embodiments, the decor layer comprises recycled PVC material.

[0180] When only two layers are present, the second layer (typically the glass fibre layer) will preferably be impregnated prior to adding the decorative layer.

[0181] In some embodiments, the multilayer PVC floor covering as disclosed herein further comprises a wear layer. In some embodiments, the wear layer is applied on the decorative layer. In some embodiments, the wear layer is applied on the printing layer or the printing pattern that is printed on the decor layer or on the third layer of the PVC floor covering intermediate sheet. When choosing a suitable material for the wear layer, high transparency and lack of own colour are preferred features. Such a wear layer allows to protect a printed layer from wearing out. Lack of wear layer colour is important to obtain a design without any colour deviations. Most preferably, the wear layer and or the decorative layer comprise PVC. In some embodiments, the multilayer PVC floor covering as disclosed herein comprises a lacquer layer. In some embodiments, the multilayer PVC floor covering comprises a lacquer layer that is applied onto the wear layer. The lacquer layer may be seen as an additional layer, or as part of the decorative layer. The lacquer layer may be a polyurethane (PU) lacquer layer. A lacquer layer may enhance scratch resistance, peeling resistance, UV resistance, and / or reduce gloss.

[0182] The PVC floor covering intermediate sheet and the PVC floor covering as disclosed herein are both compliant with any of the following standards (non-limitative list): EN ISO 24346 (total thickness), EN ISO 23997 (total weight), EN ISO 23999 (dimensional stability), EN ISO 23999 (curling), EN ISO 24343-1 (residual indentation), DIN 51130 (slip resistance), EN ISO 9237 (air permeability), EN ISO 432 (tear strength), EN ISO 527 (tensile strength), EN ISO 24345 (delamination strength).

[0183] The multilayer PVC floor covering intermediate sheet and the multilayer PVC floor covering as disclosed herein thus provide an intermediate sheet or floor covering with a significantly increased amount of recycled PVC content, but also with improved optimal mechanical properties, as well as improved insulation and / or acoustic properties. More specifically, the PVC floor covering intermediate sheet comprising recycled PVC as disclosed herein typically provides a lamination strength that is above 25 N, preferably above 30 N. In addition, the intermediate sheet and the final floor covering as disclosed herein have a dimensional stability of less than 0.10% (as measured according to EN ISO 23999), a curling of less than 8.0 mm (as measured according to EN ISO 23999), and an indent of less than 0.30 mm (as measured according to EN ISO 24343-1). Furthermore, also an increased tear strength, and increased tensile strength are obtained.

[0184] After lamination two or more layers in the PVC flooring intermediate sheet of the invention may or may not be macroscopically indistinguishable but may still be distinguishable on a molecular and / or microscopic level.

[0185] A further aspect provides a method for manufacturing a multilayer PVC floor covering intermediate sheet as disclosed herein. Said method comprises the steps of: providing a first batch of recycled PVC material; optionally mixing the first batch of recycled PVC material with one or more first components to form a first mixture; melting the first batch of recycled PVC material or the first mixture to form a first film; adhering the first film to one side of a glass fibre layer, thereby forming a multilayer structure comprising a first layer formed by the first film, and a second layer formed by the glass fibre layer, thereby forming a multilayer PVC floor covering intermediate sheet according to any of the embodiments disclosed herein. Also provided herein is a method for manufacturing a multilayer PVC floor covering intermediate sheet according to any of the embodiments disclosed herein. Said method comprises the steps of: providing first batch of recycled PVC material and a second batch of recycled PVC material; optionally mixing the first batch of recycled PVC material with one or more first components to form a first mixture; optionally mixing the second batch of recycled PVC material with one or more second components to form a second mixture; melting the first batch of recycled PVC material or the first mixture to form a first film; melting the second batch of recycled PVC material or the second mixture to form a second film; and, adhering the first film to one side of a glass fibre layer and adhering the second film to the other side of a glass fibre layer forming a multilayer structure comprising a first layer formed by the first film, a second layer formed by the glass fibre layer and a third layer formed by the second film; thereby forming a multilayer PVC floor covering intermediate sheet according to any of the embodiments as disclosed herein.

[0186] Also provided is a method for the manufacture of a PVC floor covering intermediate sheet according to any of the embodiments as disclosed herein, wherein the method comprises the steps of:

[0187] (a) providing a glass fibre layer comprising glass fibres and a binder, wherein the free volume in the glass fibre layer is at least 255.10-6m3 / m2;

[0188] (b) providing a first film comprising recycled PVC material;

[0189] (c) laminating the first film of step (b) to the glass fibre layer of step (a), thereby forming a PVC floor covering intermediate sheet comprising a first layer formed by the first film and a second layer formed by the glass fibre layer.

[0190] In some further embodiments, step (b) of said method comprises providing a second film comprising recycled PVC material and step (c) further comprises laminating the second film to the glass fibre layer on the opposite side to the first film, thereby forming a PVC floor covering intermediate sheet comprising a first layer formed by the first film, a second layer formed by the glass fibre layer, and a third layer formed by the second film.

[0191] In some embodiments, step (b) of the method comprises providing a first batch of recycled PVC material, melting the first batch of recycled PVC material to form the first film. In some further embodiments, step (b) of the method comprises providing a first batch of recycled PVC material, providing a second batch of recycled PVC material, melting the first batch of recycled PVC material to form the first film, and melting the second batch of recycled PVC material to form the second film.

[0192] In some embodiments, the first film and the glass fibre layer, and optionally the second film are laminated together to form the PVC floor covering intermediate sheet by heating. In some embodiments, heating is performed at a temperature from 100.0°C to 180.0°C; preferably from 120.0°C to 180.0°C; more preferably from 140.0°C to 18O.°C.

[0193] As used herein, lamination can be performed using heated lamination rolls

[0194] Also provided is a PVC floor covering intermediate sheet as manufactured according to any of the methods as disclosed herein.

[0195] In another aspect, the invention relates to an apparatus or production line for manufacturing a multilayer PVC floor covering intermediate sheet or a multilayer PVC floor covering, wherein the apparatus or production line is configured for performing a method as described herein and (preferred) embodiments thereof. (Preferred) embodiments of the methods as described herein are also (preferred) embodiments of an apparatus or production line as described herein, and vice versa.

[0196] The apparatus or production line preferably comprises a section configured for melting the first and / or second batch of recycled PVC material or for mixing and melting the first and / or second mixture.

[0197] In an embodiment, the apparatus or production line comprises a section configured for processing first and / or second batch of recycled PVC material or the first and / or second mixture. The apparatus or production line preferably comprises calendar rolls to process the first batch or first mixture. The apparatus or production line preferably comprises calendar rolls to process the second batch or mixture. The apparatus or production line preferably comprises a guiding system to a lamination point, preferably following the calendar rolls. The apparatus or production line preferably comprises a lamination station, preferably configured to laminate the layers at the lamination point. The lamination station may comprise lamination rolls or cooling rolls.

[0198] The apparatus or production line preferably comprises a section configured for processing the first and optionally the second batch of recycled PVC material. The apparatus or production line preferably comprises calendar rolls following the first extruder, for example two calendar rolls. The apparatus or production line preferably comprises calendar rolls following the second extruder, for example two calendar rolls. The apparatus or production line preferably comprises a guiding system to a lamination point, preferably following the calendar rolls. The apparatus or production line preferably comprises a lamination station, preferably configured to laminate the layers at the lamination point. The lamination station may comprise lamination rolls or cooling rolls.

[0199] In some embodiments, the apparatus or production line may comprise a section configured for melting the first batch of recycled PVC material; a section for processing the first batch of melted recycled PVC material, preferably a first extruder; one or more calendar rolls following the section for processing the first batch of melted recycled PVC material for processing the first batch to form the first film; a lamination station configured to laminate the first film and the glass fibre layer into a multilayer PVC floor covering intermediate sheet.

[0200] In some embodiments, the apparatus or production line comprises:

[0201] - a section configured for processing the first batch, and optionally the second batch, of recycled PVC material; preferably a section comprising a first extruder and optionally a second extruder,

[0202] - one or more calendar rolls to process the first batch, and optionally one or more calendar rolls to process the second batch, of recycled PVC material into a first film and optionally a second film;

[0203] - a section configured for providing the glass fibre layer;

[0204] - a lamination station configured to laminate the first film, the glass fibre layer, and optionally the second film, into a multilayer PVC floor covering intermediate sheet.

[0205] In some embodiments, the apparatus or production line may comprise a section configured for melting the first batch of recycled PVC material; a section configured for melting the second batch of recycled PVC material; a section for processing the first batch of melted recycled PVC material, preferably a first extruder; a section for processing the second batch of melted recycled PVC material, preferably a second extruder; one or more calendar rolls following the section for processing the first batch of melted recycled PVC material for processing the first batch to form the first film; one or more calendar rolls following the section for processing the second batch of melted recycled PVC material for calendaring the second batch to form the second film; a section configured for providing the glass fibre layer, a lamination station configured to laminate the first film, the glass fibre layer and the second film into a multilayer PVC floor covering intermediate sheet.

[0206] This disclosure also comprises aspects wherein all of the above also applies to other types of coverings, such as wall coverings, ceilings and roofings. Also provided is therefore a multilayer PVC covering intermediate sheet comprising a first layer and a second layer, wherein the first layer comprises recycled PVC material and the second layer comprises glass fibres and a binder, the intermediate sheet being characterized in that the second layer has a free volume of at least 255.10'6m3 / m2. In preferred embodiments, said PVC covering intermediate sheet is a PVC wall covering intermediate sheet, a PVC ceiling covering intermediate sheet or a PVC roof covering intermediate sheet.

[0207] Further provided is a multilayer PVC covering comprising such a multilayer PVC covering intermediate sheet. In some embodiments, the multilayer PVC covering is a multilayer PVC wall covering, a multilayer PVC ceiling covering or a multilayer PVC roof covering.

[0208] Also provided is a method for the manufacture of a PVC covering intermediate sheet, the method comprising the steps of:

[0209] (a) providing a glass fibre layer comprising glass fibres and a binder, wherein the free volume in the glass fibre layer is at least 255.10-6m3 / m2;

[0210] (b) providing a first film comprising recycled PVC material;

[0211] (c) laminating the first film of step (b) to the glass fibre layer of step (a), thereby forming a PVC covering intermediate sheet (10) comprising a first layer (1) formed by the first film and a second layer (2) formed by the glass fibre layer.

[0212] Further provided is a PVC covering intermediate sheet as manufactured by said method.

[0213] Preferred embodiments of these aspects are as the preferred embodiments as disclosed above for the PVC floor covering intermediate sheet, the PVC floor covering, and the method to manufacture such PVC floor covering intermediate sheet.

[0214] EXAMPLES

[0215] The following examples serve to merely illustrate the invention and should not be construed as limiting its scope in any way. While the invention has been shown in only some of its forms, it should be apparent to those skilled in the art that it is not so limited, but is susceptible to various changes and modifications without departing from the scope of the invention.

[0216] FIG. 1 illustrates a PVC floor covering intermediate sheet (10) according to an embodiment of the invention. The intermediate sheet (10) comprises a first layer (1) and a second layer (2).

[0217] FIG. 2 illustrates a PVC floor covering (20) according to an embodiment of the invention. The floor covering (20) comprises a PVC floor covering intermediate sheet (10) with a first (1) and a second (2) as disclosed herein, and a backing layer (21). FIG. 3 illustrates a PVC floor covering (20) according to an embodiment of the invention. The floor covering (20) comprises a PVC floor covering intermediate sheet (10) with a first (1) and a second (2) layer as disclosed herein, and a decorative layer (22).

[0218] FIG. 4 illustrates a PVC floor covering (20) according to an embodiment of the invention. The floor covering (20) comprises a PVC floor covering intermediate sheet (10) with a first (1) and a second (2) layer as disclosed herein, and a decor layer (23) and a print layer (24), together forming the decorative layer (22).

[0219] FIG. 5 illustrates a PVC floor covering (20) according to an embodiment of the invention. The floor covering (20) comprises a PVC floor covering intermediate sheet (10) with a first (1) and a second (2) layer as disclosed herein, and a decorative layer (22) and a wear layer (25).

[0220] FIG. 6 illustrates a PVC floor covering (20) according to an embodiment of the invention. The floor covering (20) comprises a backing layer (21), a PVC floor covering intermediate sheet (10) with a first (1) and a second (2) layer as disclosed herein, and a decorative layer (22) and a wear layer (25).

[0221] FIG. 7 illustrates a PVC floor covering intermediate sheet (10) according to an embodiment of the invention. The intermediate sheet (10) comprises a first layer (1), a second layer (2) and a third layer (3).

[0222] FIG. 8 shows a microscopic image of a PVC floor covering intermediate sheet (10) according to an embodiment of the invention. The intermediate sheet (10) comprises a first layer (1) and a third layer (3), each comprising recycled PVC material, and both layers are laminated onto a second layer (2), which is a glass fibre web. After lamination, the three layers may be difficult to distinguish, or not visually distinguishable anymore.

[0223] FIG. 9 illustrates a PVC floor covering (20) according to an embodiment of the invention. The floor covering (20) comprises a PVC floor covering intermediate sheet (10) with a first (1), a second (2) and a third layer (3) as disclosed herein, and a backing layer (21).

[0224] FIG. 10 illustrates a PVC floor covering (20) according to an embodiment of the invention. The floor covering (20) comprises a PVC floor covering intermediate sheet (10) with a first (1), a second (2) and a third layer (3) as disclosed herein, and a decorative layer (22).

[0225] FIG. 11 illustrates a PVC floor covering (20) according to an embodiment of the invention. The floor covering (20) comprises a PVC floor covering intermediate sheet (10) with a first (1), a second (2) and a third layer (3) as disclosed herein, and a decor layer (23) and a print layer (24), together forming the decorative layer (22). FIG. 12 illustrates a PVC floor covering (20) according to an embodiment of the invention. The floor covering (20) comprises a PVC floor covering intermediate sheet (10) with a first (1), a second (2) and a third layer (3) as disclosed herein, and a decorative layer (22) and a wear layer (25).

[0226] FIG. 13 illustrates a PVC floor covering (20) according to an embodiment of the invention. The floor covering (20) comprises a backing layer (21), a PVC floor covering intermediate sheet (10) with a first (1), a second (2) and a third layer (3) as disclosed herein, and a decorative layer (22) and a wear layer (25).

[0227] FIG. 14 illustrates a flow chart of the different steps in a method to manufacture a PVC floor covering intermediate sheet (10) according to an embodiment of the invention. Following steps are illustrated in FIG. 14:

[0228] 101 - providing a first batch of recycled PVC material

[0229] 102 - providing a second batch of recycled PVC material

[0230] 103 - melting the first batch of recycled PVC material to form a first film

[0231] 104 - melting the second batch of recycled PVC material to form a second film

[0232] 105 - adhering the first film to one side of a glass fibre layer

[0233] 106 - adhering the second film to the other side of the glass fibre layer

[0234] 107 - heating the multilayer structure, thereby forming a multilayer PVC floor covering intermediate sheet according to any one of claims 1 to 8.

[0235] Further examples illustrate the improved properties of embodiments according to the invention.

[0236] The examples in Table 1 were performed with a full glass fibre layer, before it is incorporated into a multilayer intermediate sheet according to an embodiment of the invention.

[0237] The examples in Table 2 were performed with 98.6% of PVC recycled material, with roughly 30-40% PVC. MD refers to Machine direction and CD refers to Cross direction.

[0238] In Table 3, the following floor covering samples were used:

[0239] Floor covering sample 1 : a first layer comprising 45% recycled content of PVC and a second layer of glass fibres.

[0240] Floor covering sample 2: a first layer comprising 27% recycled content of PVC and a second layer of glass fibres. Floor covering sample 3 (Control): a first layer comprising virgin PVC and no recycled PVC and a second layer of glass fibres. The glass fibre is the Control Sample of T able 1.

[0241] In a further example, and as shown in Table 4, thickness and area weight of a glass fibre layer were measured before it is incorporated into a multilayer intermediate sheet according to an embodiment of the invention (sample 10), and after incorporation into a multilayer intermediate sheet according to an embodiment of the invention (sample 11). More specific, for sample 11 , the glass fibre layer was incorporated into a PVC floor covering intermediate sheet that further comprises a first and a third layer comprising recycled PVC material. Measurements of sample 11 were then preformed after isolation of the glass fibre layer (second layer) using a method with tetrahydrofuran as disclosed herein. Briefly, in said method, the second glass fibre layer was separated from the first and third PVC comprising layers using tetra hydrofuran, thereby dissolving the PVC layers. Therefore, the intermediate sheet was rinsed in tetrahydrofuran at a temperature of approximately 25°C. After the PVC layers were completely dissolved, the glass fibre layer was rinsed in ethanol to remove any residual polymer and solvent. Thereafter, thickness and area weight of the glass fibre layer were measured according to a method disclosed herein. As shown in Table 4, the thickness and area weight of sample 11 only slightly differed from the thickness and area weight of sample 10. As such, also the free volume of sample 11 was similar to that of sample 10.

[0242] Table 1. Analysis of the glass fibre layer (second layer) as used in a PVC floor covering intermediate sheet according to an embodiment of the invention

[0243] Table 2. Features of different types of PVC floor covering intermediate sheet according to an embodiment of the invention.

[0244] Table 3. Characteristics of different PVC floor covering samples according to an embodiment of the invention.

[0245] Table 4. Analysis of the glass fibre layer (second layer) as used in a PVC floor covering intermediate sheet according to an embodiment of the invention Sample 10 represents a glass fibre layer prior to incorporation in a PVC floor covering intermediate sheet, whereas Sample 11 represents a glass fibre layer (second layer) after incorporation in a PVC floor covering intermediate sheet that further comprises a first and a third layer comprising recycled PVC material. Measurements of Sample 11 are preformed after isolation of the glass fibre layer using a method 5 with tetrahydrofuran as disclosed herein.

Claims

CLAIMS1. A method for the manufacture of a PVC floor covering intermediate sheet (10) , the method comprising the steps of:(a) providing a glass fibre layer comprising glass fibres and a binder, wherein the free volume in the glass fibre layer is at least 255.1 O'6m3 / m2;(b) providing a first film comprising recycled PVC material;(c) laminating the first film of step (b) to the glass fibre layer of step (a), thereby forming a PVC floor covering intermediate sheet (10) comprising a first layer (1) formed by the first film and a second layer (2) formed by the glass fibre layer.

2. The method of claim 1 , wherein step (b) further comprises providing a second film comprising recycled PVC material and step (c) further comprises laminating the second film to the glass fibre layer on the opposite side to the first film, thereby forming a PVC floor covering intermediate sheet (10) comprising a first layer (1) formed by the first film, a second layer (2) formed by the glass fibre layer, and a third layer (3) formed by the second film.

3. The method of claim 1 or 2, wherein step (b) comprises:- providing a first batch of recycled PVC material;- optionally, providing a second batch of recycled PVC material;- melting the first batch of recycled PVC material to form the first film;- optionally, melting the second batch of recycled PVC material to form the second film.

4. The method of any one of claims 1 to 3, wherein the glass fibre layer provided in step (a) has an air permeability of at least 5000 l / m2.s as measured according to DIN EN ISO 9237.

5. The method of any one of claims 1 to 4, wherein the glass fibre layer provided in step (a) has an air permeability of at least 12000 l / m2.s as measured according to DIN EN ISO 9237.

6. The method of any one of claims 1 to 5, wherein the first film and optionally the second film (3) each independently comprise at least 50% recycled PVC material; preferably at least 70%; more preferably at least 80%, or at least 90% recycled PVC material, based on the total weight of the first film and optionally the second film respectively, such as for example 95%, or 98%, or 100% recycled PVC material, based on the total weight of the first film and optionally the second film, respectively.

7. The method of any one of claims 1 to 6, wherein the recycled PVC material comprises at least 20% recycled PVC, preferably at least 40%, more preferably at least 60%, at least 70% or at least 80%, recycled PVC based on the total weight of the recycled PVC material, such as for example 90%, or 95%, or 98% or 100% recycled PVC, based on the total weight of the recycled PVC material.

8. The method of any one of claims 1 to 7, wherein the glass fibre layer provided in step (a) comprises at most 40% by weight binder, based on the total weight of the glass fibre layer (2), preferably at least 10% by weight to at most 30% by weight, for example about 20% by weight.

9. A PVC floor covering intermediate sheet (10) as manufactured by a method according to any one of claims 1 to 8.

10. A PVC floor covering intermediate sheet (10) comprising a first layer (1) and a second layer (2), wherein the first layer (1) comprises recycled PVC material and the second layer (2) comprises glass fibres and a binder, the intermediate sheet characterized in that the second layer has a free volume of at least 255.1 O'6m3 / m2.

11. The PVC floor covering intermediate sheet of claim 10 further comprising a third layer (3) comprising recycled PVC material.

12. The PVC floor covering intermediate sheet of claim 10 or 11 , wherein the second layer (2) in the intermediate sheet has an air permeability of at least 5000 l / m2.s as measured according to DIN EN ISO 9237; preferably an air permeability of at most 12000 l / m2.s as measured according to DIN EN ISO 9237.

13. The PVC floor covering intermediate sheet (10) of any one of claims 10 to 12, wherein the first layer (1) and optionally the third layer (2) each independently comprise at least 50% recycled PVC material, preferably at least 70%; more preferably at least 80% or at least 90% recycled PVC material, based on the total weight of the first layer (1) and the third layer (3) respectively; such as for example 95%, or 98% or 100% recycled PVC material, based on the total weight of the first layer (1) and optionally the third layer (3) respectively.

14. The PVC floor covering intermediate sheet (10) of any one of claims 10 to 13, wherein the recycled PVC material comprises at least 20% recycled PVC, preferably at least 40%, more preferably at least 60%, at least 70% or at least 80%, recycled PVC based on the total weightof the recycled PVC material, such as for example 90%, or 95%, or 98% or 100% recycled PVC, based on the total weight of the recycled PVC material.

15. The PVC floor covering intermediate sheet (10) of any one of claims 11 to 14, wherein the second layer is located on top of the first layer and the third layer is located on top of the second layer.

16. The PVC floor covering intermediate sheet (10) of any one of claims 10 to 15, wherein the second layer (2) comprises at most 40% by weight binder, based on the total weight of the second layer (2), preferably at least 10% by weight to at most 30% by weight, for example about 20% by weight.

17. A multilayer PVC floor covering (20) comprising the PVC floor covering intermediate sheet (10) of any one of claims 9 to 16.

18. The multilayer PVC floor covering (20) of claim 17, further comprising a backing layer (21), preferably wherein the intermediate sheet is located on top of the backing layer (21); more preferably wherein the first layer (1) of the intermediate sheet (10) is in contact with the backing layer (21).

19. The multilayer PVC floor covering (20) of claim 17 or 18, further comprising a decorative layer (22); preferably wherein the decorative layer (22) is located on top of the intermediate sheet (10).

20. The multilayer PVC floor covering (20) of claim 19, wherein the decorative layer comprises a decor layer (23); preferably wherein the decorative layer comprises a decor layer (23) and a print layer (24).21 . The multilayer PVC floor covering (20) of any one of claims 9 to 20, further comprising a wear layer (25); preferably wherein the wear layer is located on top of the decorative layer (22); more preferably wherein the wear layer is located on top of the print layer (24).

22. Apparatus for manufacturing a multilayer PVC floor covering intermediate sheet (10) or a multilayer PVC floor covering (20) wherein the apparatus is configured for performing a method according to any one of claims 1 to 8.

23. The apparatus of claim 22, wherein the apparatus comprises:- a section configured for processing the first batch, and optionally the second batch, of recycled PVC material; preferably wherein said section comprises a first extruder and optionally a second extruder;- one or more calendar rolls to process the first batch, and optionally one or more calendar rolls to process the second batch, of recycled PVC material into a first film and optionally a second film;- a section configured for providing the glass fibre layer;- a lamination station configured to laminate the first film, the glass fibre layer and optionally the second film, into a multilayer PVC floor covering intermediate sheet.

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