Multilayer floor covering and method for the manufacturing of said floor covering

Abstract

The present invention relates to a multilayer floor covering and a method to produce such a multilayer floor covering. The multilayer floor covering is typically characterized in that it comprises a backing layer having an air permeability of at least 500 l / m2 / s measured at 200 Pascal according to ISO 9237, a coating layer based on a polymer-in-water dispersion, and a wear layer wherein each of these layers comprise a thermoplastic polymer that is of the same family of thermoplastic polymers and that are each essentially free of PVC homopolymers and PVC copolymers. Also a method to produce such a multilayer floor covering is provided.

Description

[0001] MULTILAYER FLOOR COVERING AND METHOD FOR THE MANUFACTURING OF SAID FLOOR COVERING

[0002] TECHNICAL FIELD

[0003] The present invention in general relates to a multilayer floor covering comprising at least a backing layer, a coating layer, and a wear layer that are essentially free of polyvinyl chloride (PVC) homopolymers and PVC copolymers and a method for producing such a multilayer floor covering.

[0004] BACKGROUND

[0005] Conventional floor coverings often comprise polyvinylchloride (PVC) for its durability, flexibility, and cost-effectiveness.

[0006] However, use of PVC flooring is under pressure for a variety of regulatory, environmental and health concerns, and is currently being investigated by regulators in the European Commission (ECHA) and certain member states, as well by some states in the USA. These investigations are based on health concerns from the so-called legacy plasticizers and additives used in flexible vinyl floorcoverings, as well disposal challenges when PVC is incinerated uncontrolled, it can release toxic gases. Besides potential regulatory restrictions, some regions in Europe avoid the use in certain applications such as schools and public buildings. PVC is also on the restricted chemicals list of Cradle-to-Cradle.

[0007] There is thus an increasing regulatory and consumer demand for more sustainable and safer materials has driven the need for innovative flooring solutions that reduce or even eliminate the use of PVC and also plasticizers.

[0008] The present invention provides a future product alternative for those customers that look for an economical product with similar properties to current vinyl floor coverings.

[0009] Alternatives to avoid PVC and / or plasticizers in floor coverings are available but these alternatives still have limitations compared to PVC-based floor coverings, notably with regard to mechanical properties such as product flexibility, dimensional stability, surface hardness, indentation resistance and scratch resistance. Also, there are generally still one or more layers present that still comprise PVC and / or plasticizers. Furthermore, the production process of these alternatives is often different from the production process of floor coverings comprising PVC and / or plasticizers, which makes the transition of production lines in a factory costly and time-consuming.

[0010] 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 floor covering that allows to eliminate PVC, and optionally also plasticizers, required for its production, thereby also eliminating the environmental and health concerns associated with PVC and plasticizers. It is also an objective to provide a multilayer floor covering that eliminates PVC, and optionally plasticizers, wherein the floor covering has optimal mechanical properties, insulation, and / or acoustic properties.

[0011] It is also an objective to provide a method for production of a floor covering that eliminates the use of PVC, and optionally plasticizers, but wherein the existing production plants of cushion vinyl floor coverings can be easily converted to production plants that allow the production of a multilayer floor covering according to the invention.

[0012] SUMMARY OF THE INVENTION

[0013] 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.

[0014] The invention is defined by the independent patent claims. The dependent claims define advantageous embodiments of the invention.

[0015] The inventors have developed a multilayer floor covering that eliminates the use of PVC and optionally also the use of plasticizers. Specifically, the multilayer floor covering comprises in the following order at least a backing layer, a coating layer based on a polymer-in-water dispersion and a wear layer. Preferred for the present invention is that the backing layer, the coating layer, and the wear layer are each essentially free of PVC homopolymers and PVC copolymers and that these layers each comprise a thermoplastic polymer wherein said thermoplastic polymer in each layer is of the same family of thermoplastic polymers. Also preferred is that the backing layer has an air permeability of at least 500 l / m2 / s measured at 200 Pascal according to ISO 9237, such that the after application of the coating layer, which is based on a polymer-in-water dispersion, sufficient water from the coating layer can evaporate through the backing layer such that the different layers can be fused in a robust manner. In some preferred embodiments, the multilayer floor covering is essentially free of PVC homopolymers and PVC copolymers. In some preferred embodiments, the backing layer, the coating layer, and the wear layer are each essentially free of any polymer other than the thermoplastic polymer. As such, a multilayer floor covering is created wherein only one family of thermoplastic polymer is present in the backing layer, the coating layer, and the wear layer. More preferably, the multilayer floor covering is essentially free of any polymer other than the thermoplastic polymer. Further preferred, is that the multilayer floor covering as disclosed herein has a bending stiffness of at most 800 N.mm, preferably as measured by the bending stiffness test disclosed herein, more preferably by a modified bending test according to ISO 5628 as disclosed herein. As such, even in the absence of PVC and optionally also in the absence of plasticizers, a flexible floor covering product is created.

[0016] The inventors have also developed a production method to produce a multilayer floor covering as disclosed herein, wherein a wear layer is provided whereafter a coating layer based on a polymer-in-water dispersion is applied on the wear layer followed by applying a backing layer on the coating layer, wherein the backing layer is configured to overlie the coating layer such that the backing layer contacts the coating layer.

[0017] Another aspect provides a production method to produce a multilayer floor covering as disclosed herein, wherein a backing layer is provided whereafter a coating layer based on a polymer-in-water dispersion is applied on the backing layer followed by applying a wear layer on the coating layer, wherein the wear layer is configured to overlie the coating layer such that the wearing layer contacts the coating layer.

[0018] The advantage of the production methods disclosed herein is that they eliminate the use of PVC, and optionally also the use of plasticizers.

[0019] The present invention provides a cost-competitive and durable multilayer floor covering equivalent to a plasticized heterogenous vinyl floor covering but without using PVC and / or plasticizers. The multilayer floor covering of the present invention thus achieves the desirable properties of durability, flexibility, and aesthetic appeal without the environmental and health drawbacks associated with PVC. In particular, the floor covering of the present invention is characterized in that it comprises at least a wear layer, a coating layer, and a backing layer that are all essentially free of PVC and optionally essentially free of plasticizers and wherein the floor covering still provides the necessary mechanical and scratch resistance properties. In some embodiments, the multilayer floor covering has a bending stiffness of at most 800 N.mm, preferably as measured according to the bending stiffness test disclosed herein, more preferably as measured according to a modified bending stiffness test according to ISO 5628 as disclosed herein, even in the absence of PVC and / or plasticizers.

[0020] Also provided is a method to produce a multilayer floor covering that comprises a wear layer, a coating layer, and a backing layer that are all essentially free of PVC and optionally essentially free of plasticizers.

[0021] Finally, the multilayer floor covering of the invention provides benefits to recycling and take- back of used floorings since it can be part of existing recycling processes of thermoplastic polymers, such as polypropylene (PP) or polyethylene terephthalate (PET).

[0022] In a first aspect, the invention relates to a multilayer floor covering comprising, in following order, at least a backing layer, a coating layer based on a polymer-in-water-dispersion, and a wear layer, wherein the backing layer, the coating layer, and the wear layer each comprise a thermoplastic polymer wherein said thermoplastic polymer in each layer is of the same family of thermoplastic polymers and wherein the backing layer, the coating layer, and the wear layer are essentially free of polyvinyl (PVC) homopolymers and PVC copolymers. The backing layer is further characterized in that it has an air permeability of at least 500 l / m2 / s measured at 200 Pascal according to ISO 9237.

[0023] In some preferred embodiments, the backing layer, the coating layer, and the wear layer are each essentially free of any polymer other than the thermoplastic polymer that is of the same family of thermoplastic polymers..

[0024] In some preferred embodiments, the multilayer floor covering is essentially free of any polymer other than the thermoplastic polymer that is of the same family of thermoplastic polymers.

[0025] In some preferred embodiments, the thermoplastic polymer is a polymer of the family of polyolefins, polystyrenes, polyesters, or polyamides; more preferably of the family of polyolefins, polystyrenes or polyamides. In some further preferred embodiments, the thermoplastic polymer is selected from the group consisting of polypropylene (PP), polyethylene (PE), ethylene-propylene copolymer, ethylene-butene copolymer, ethyleneoctene copolymer, butadiene-propylene copolymer, ethylene vinyl acetate (EVA), ethylene methyl acetate (EMA), polystyrene (PS), styrene-propylene copolymer, polyethylene terephthalate (PET), co-PET, polyethylene terephthalate glycol (PETG), polybutylene terephthalate (PBT), polylactic acid (PLA), polycaprolactone (PCL) , polyamide, and copolyamide. In some embodiments, the thermoplastic polymer is selected from polyethylene (PE), polypropylene (PP), ethylene-propylene copolymer, ethylene-butene copolymer, ethylene-octene copolymer, polyethylene terephthalate glycol, polybutylene terephthalate, polyethylene terephthalate (PET), and co-PET. Preferably, the thermoplastic polymer is a thermoplastic polymer of the family of polyolefins or polyesters, such as PP, or PET, or co- PET. In some embodiments, the backing layer, the coating layer, and the wear layer each comprise a polyolefin or a polyester.

[0026] In some embodiments, the thermoplastic polymer is a recycled thermoplastic polymer.

[0027] The multilayer floor covering of the invention is preferably characterized in that at least the backing layer, the coating layer and the wear layer are essentially free of PVC. In some preferred embodiments, the multilayer floor covering is essentially free of PVC.

[0028] In some embodiments, the multilayer floor covering is preferably characterized in that at least the backing layer, the coating layer, and the wear layer are essentially free of plasticizers. In some preferred embodiments, the multilayer floor covering is essentially free of plasticizers. In some embodiments, the multilayer floor covering is characterized in that at least the backing layer, the coating layer and the wear layer are essentially free of PVC and essentially free of plasticizers. In some preferred embodiments, the multilayer floor covering is essentially free of PVC and essentially free of plasticizers.

[0029] In some embodiments, the backing layer is a non-woven backing layer; preferably a nonwoven textile backing layer.

[0030] In some embodiments, the backing layer is a woven backing layer; preferably a woven textile backing layer.

[0031] In some embodiments, the backing layer comprises an additional layer of glass fibre tissue.

[0032] In order to allow sufficient water evaporation from the coating layer it is particularly preferred that the backing layer has a high rate of air permeability. In some preferred embodiments, the air permeability of the backing layer is at least 500 l / m2 / s, preferably at least 750 l / m2 / s, more preferably at least 1000 l / m2 / s, even more preferably at least 1250 l / m2 / s, measured at 200 Pascal according to ISO 9237.

[0033] In some embodiments, the multilayer floor covering has a bending stiffness of at most 800.0 N.mm as measured using the bending stiffness test disclosed herein, in particular as measured using a modified bending stiffness test according to ISO 5628 wherein the bending angle is set at 30° as disclosed herein. In some further embodiments, the multilayer floor covering has a bending stiffness of at most 600.0 N.mm, preferably at most 450 N.mm, more preferably at most 350 N.mm, as measured using the bending stiffness test disclosed herein, in particular as measured using a modified bending stiffness test according to ISO 5628 wherein the bending angle is set at 30°.

[0034] In some embodiments, the multilayer floor covering has a bending stiffness of at least 5.0 N.mm as measured using the bending stiffness test disclosed herein, in particular as measured using a modified bending stiffness test according to ISO 5628 wherein the bending angle is set at 30° as disclosed herein. In some further embodiments, the multilayer floor covering has a bending stiffness of at least 100.0 N.mm, preferably at least 150.0 N.mm, more preferably at least 180.0 N.mm, as measured using the bending stiffness test disclosed herein, in particular as measured using a modified bending stiffness test according to ISO 5628 wherein the bending angle is set at 30°.

[0035] In some embodiments, the multilayer floor covering has a bending stiffness of at least 5.0 N.mm and at most 800.0 N.mm as measured using to the bending stiffness test disclosed herein. Preferably, the bending stiffness is of at least 100.0 N.mm and at most 600.0 N.mm, more preferably of at least 150 N.mm and at most 450 N.mm; even more preferably of at least 180 N.mm to at most 350 N.mm, as measured using to the bending stiffness test disclosed herein, in particular as measured using a modified bending stiffness test according to ISO 5628 wherein the bending angle is set at 30°.

[0036] In some embodiments, the multilayer floor covering further comprises a reinforcement layer and an additional coating layer (or second coating layer) based on a polymer-in-water dispersion, wherein said reinforcement layer and additional (or second) coating layer are located in between the coating layer and the backing layer, with the additional coating layer being in contact with the backing layer and the reinforcement layer being in contact with the coating layer, and wherein the additional (or second) coating layer comprises the same thermoplastic polymer as the backing layer, the coating layer and the wear layer and wherein the additional (or second) coating layer is essentially free of polyvinyl chloride (PVC) homopolymers and PVC copolymers. Even more preferably, the additional (or second) coating layer is essentially free of plasticizers.

[0037] The floor covering of the invention preferably comprises a coating layer based on a polymer- in-water dispersion that is applied to the backing layer. In some embodiments, the floor covering comprises only one coating layer based on a polymer-in-water dispersion. In some embodiments, the floor covering comprises a (first) coating layer based on a polymer-in-water dispersion and an additional (or second) coating layer based on a polymer-in-water dispersion.

[0038] In some embodiments, and when a coating layer and an additional coating layer are present, the backing layer, the coating layer, the additional coating layer, and the wear layer each comprise a thermoplastic polymer that is of the same family of thermoplastic polymers. In some further embodiments, the backing layer, the coating layer, the additional coating layer, and the wear layer are essentially free of any polymer other than the thermoplastic polymer.

[0039] In some preferred embodiments, the polymer-in-water dispersion of the coating layer and the additional coating layer has a solid content of at least 10.0 wt%; preferably at least 30.0 wt%; more preferably at least 50.0 wt%, or at least 65.0 wt%; even more preferably at least 68.0 wt%.

[0040] In some embodiments, the solid content in the coating layer is determined by all solid components present in the polymer-in-water dispersion. In some embodiments, the solid content is determined by the polymer of the coating layer and by any additives that are present in the polymer-in-water dispersion. In some embodiments, the solid content in the coating layer is determined by the polymer of the coating layer, one or more fillers present in the coating layer, and any other solid components present in the polymer-in-water dispersion. In some embodiments, the solid content in the coating layer is determined only by the polymer of the coating layer. In some embodiments, the coating layer and / or additional coating layer is a foamed coating layer.

[0041] In some embodiments, the coating layer and / or additional coating layer is a non-foamed coating layer.

[0042] In some embodiments, the wear layer comprises one thermoplastic polymer, such as one polymer selected from the group consisting of polypropylene (PP), polyethylene (PE), ethylene-propylene copolymer, ethylene-butene copolymer, ethylene-octene copolymer, ethylene vinyl acetate (EVA), ethylene methyl acetate (EMA), polystyrene (PS), styrenepropylene copolymer, polyethylene terephthalate (PET), co-PET, polyethylene terephthalate glycol (PETG), polybutylene terephthalate (PBT), polylactic acid (PLA), polycaprolactone (PCL), polyamide, and co-polyamide. In some embodiments, the wear layer comprises a thermoplastic polymer of the family of polyolefins or polyesters and no other polymers. In some embodiments, the wear layer is a mono-polymer material wear layer wherein only one type of thermoplastic polymer is present.

[0043] In some preferred embodiments, the wear layer comprises a print pattern deposited on the surface of the wear layer on the side of the coating layer. In some embodiments, the wear layer comprises a print pattern deposited on the surface of the wear layer. In some embodiments, such print pattern is deposited on the surface of the wear layer during the production process of the floor covering. In other embodiments, such print pattern is deposited on the surface of the wear layer prior to production of the floor covering and the wear layer is provided with a printed pattern.

[0044] In some embodiments, the wear layer is an embossed wear layer; such as a thermally embossed wear layer, a cold embossed wear layer, or an embossed wear layer generated through a casting process.

[0045] In some embodiments, the multilayer floor covering further comprises a lacquer layer that is located on the wear layer; preferably wherein the lacquer comprises polyurethane, polyacrylate, or a mixture thereof.

[0046] In some embodiments, the lacquer layer is essentially free of PVC homopolymers and PVC copolymers. In some embodiments, the lacquer layer is essentially free of plasticizers.

[0047] In some embodiments, the multilayer floor covering is essentially free of PVC homopolymers and PVC copolymers. In some embodiments, the multilayer floor covering is essentially free of plasticizers.

[0048] Another aspect provides a method to produce a multilayer floor covering; preferably a method to produce a multilayer floor covering according to any of the embodiments described herein. In some embodiments, the method comprises the steps of: a) providing a wear layer; b) applying a coating layer based on a polymer-in-water dispersion on the wear layer; and, c) applying a backing layer on the coating layer, wherein the backing layer is configured to overlie the coating layer such that the backing layer contacts the coating layer; wherein the backing layer, the coating layer, and the wear layer each comprise a thermoplastic polymer wherein said thermoplastic polymer in each layer is of the same family of thermoplastic polymers; wherein the backing layer, the coating layer, and the wear layer are essentially free of PVC homopolymers and PVC copolymers; and wherein the backing layer has an air permeability of at least 500 l / m2 / s, measured at 200 Pascal according to ISO 9237. In some embodiments, the backing layer, the coating layer and the wear layer are essentially free of plasticizers.

[0049] In some further embodiment, the method comprises a step b1) wherein after step b) a reinforcement layer is applied on the coating layer and wherein an additional coating layer based on a polymer-in-water dispersion is applied on the reinforcement layer, and wherein in step c) the backing layer is applied on the additional coating layer, wherein the backing layer is configured to overlie the additional coating layer such that the backing layer contacts the additional coating layer.

[0050] In some embodiments, the method disclosed herein comprises the steps of: a) providing a backing layer that has an air permeability of at least 500 l / m2 / s, measured at 200 Pascal according to ISO 9237; b) applying a coating layer based on a polymer-in-water dispersion on the backing layer; and c) applying a wear layer on the coating layer, wherein the wear layer is configured to overlie the coating layer such that the wear layer contacts the coating layer; wherein the backing layer, the coating layer, and the wear layer each comprise a thermoplastic polymer wherein said thermoplastic polymer in each layer is of the same family of thermoplastic polymers; and wherein the backing layer, the coating layer, and the wear layer are essentially free of PVC homopolymers and PVC copolymers.

[0051] In some embodiments, the backing layer, the coating layer and the wear layer are essentially free of plasticizers.

[0052] In some further embodiments, said method comprises a step a1) wherein after step a) an additional coating layer based on a polymer-in-water dispersion is applied on the backing layer and wherein a reinforcement layer is applied on the additional coating layer and wherein in step b) the coating layer is applied on the reinforcement layer.

[0053] In some embodiments, the method further comprises a step d) that comprises heating the floor covering to a temperature of at least 70.0°C to at most a temperature that is 20.0°C above the melting temperature of the thermoplastic polymer in the multilayer floor covering, thereby allowing the coating layer to fuse with the wear layer and the backing layer. In some further embodiments, step d) comprises heating the floor covering to a temperature of at least 70.0°C to at most a temperature that is 10.0 °C above the melting temperature of the thermoplastic polymer in the multilayer floor covering. In some further preferred embodiments, step d) comprises heating the floor covering to a temperature of at least 70.0°C to at most 270°C; preferably at least 80.0°C to at most 250°C; more preferably at least 80.0°C to at most 200°C; even more preferably at least 80°C to at most 180°C, or at least 80°C to at most 165°C, or at least 85°C to at most 160°C, or at least 85°C to at most 155°C.

[0054] In some embodiments, the wear layer is a preprinted wear layer wherein the wear layer comprises a print pattern deposited on the surface of the wear layer that is on the side of the coating layer. In some embodiments, the wear layer is a preprinted wear layer wherein the wear layer comprises a print pattern deposited on the surface of the wear layer that is on the opposite side of the coating layer.

[0055] In some embodiments, and prior to step a) or step c), a print pattern is deposited on the surface of the wear layer that is on the side of the coating layer. In some embodiments, and prior to step a) or step c), a print pattern is deposited on the surface of the wear layer that is on the opposite side of the coating layer.

[0056] In some embodiments, the method further comprises a step e) that comprises embossing of the wear layer. In some embodiments, the wear layer is thermally embossed; more preferably wherein the embossing is performed by infrared heating of the floor covering followed by cold pressing of a structure into the wear layer. In some embodiments, the wear layer is cold embossed.

[0057] In some embodiments, the method further comprises a step f) that comprises applying a lacquer layer on the wear layer; preferably wherein the lacquer layer comprises polyurethane, polyacrylate, or a mixture thereof.

[0058] In some embodiments, the method is for the manufacture of a multilayer floor covering that is essentially free of PVC homopolymers and PVC copolymers. In some further embodiments, the method is for the manufacture of a multilayer floor covering that is essentially free of plasticizers. In some further embodiments, the method is for the manufacture of a multilayer floor covering that has a bending stiffness of at most 800 N.mm, preferably as measured using to the bending stiffness test disclosed herein, more preferably as measured using a modified bending stiffness test according to ISO 5628 wherein the bending angle is set at 30°.

[0059] Another aspect provides a multilayer floor covering manufactured by the method as disclosed herein.

[0060] DETAILED DESCRIPTION OF THE FIGURES

[0061] In the following is described examples of preferred embodiments illustrated in the accompanying drawings, wherein:

[0062] FIG. 1 illustrates a multilayer floor covering (1) according to an embodiment of the invention. The floor covering (1) comprises a backing layer (2), a coating layer (3), and a wear layer (4). FIG. 2 Illustrates a multilayer floor covering (1) according to an embodiment of the invention. The floor covering (1) comprises a backing layer (2), a coating layer (3), a print pattern (5), and a wear layer (4).

[0063] FIG. 3 illustrates a multilayer floor covering (1) according to an embodiment of the invention. The floor covering (1) comprises a backing layer (2), a coating layer (3), a print pattern (5), a wear layer (4), and a lacquer layer (6).

[0064] FIG. 4 illustrates a multilayer floor covering (1) according to an embodiment of the invention. The floor covering (1) comprises a backing layer (2), an additional coating layer (7), a reinforcement layer (8), a coating layer (3), a print pattern (5) and a wear layer (4).

[0065] FIG. 5 illustrates a multilayer floor covering (1) according to an embodiment of the invention. The floor covering (1) comprises a backing layer (2), an additional coating layer (7), a reinforcement layer (8), a coating layer (3) and a wear layer (4).

[0066] FIG. 6 illustrates a schematic representation of a method for the manufacture of a multilayer floor covering according to an embodiment of the invention. A first coating layer (3a) and, optionally, a second coating layer (3b), are applied on a wear layer (4) with a print pattern (5), followed by the application of a backing layer (2) on the coating layer, thereby forming a multilayer floor covering according to an embodiment of the invention.

[0067] FIG. 7 illustrates a method for the manufacture of a multilayer floor covering according to an embodiment of the invention. In a first step, a wear layer (4) with a print pattern (5) is provided wounded on a roll (11). The wear layer (4) is coated with a coating layer (3) based on a polymer-in-water dispersion. The coating is applied at the coating station using a coating knife (12). Next, a backing layer (2) is applied on the coating layer, wherein the backing layer is configured to overlie the coating layer (3) such that the backing layer (2) contacts the coating layer (3). As shown in the figure, the backing layer (2) can be provided on a roll (13) and guided to a nip roll (14). After application of the backing layer (2) on the coating layer (3), the floor covering is laminated and heated in an air-heated oven (15) to allow the layers to fuse with each other.

[0068] 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.

[0069] DETAILED DESCRIPTION OF THE INVENTION

[0070] When describing the invention, the terms used are to be construed in accordance with the following definitions, unless the context dictates otherwise.

[0071] 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.

[0072] 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'.

[0073] As used herein, the term “in following order”, refers to a specific order of different layers of the floor covering disclosed herein. The term “in following order” does not exclude that any additional layers can be present in between the listed layers.

[0074] 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.

[0075] 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.

[0076] 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.

[0077] Unless defined otherwise, percentages are percentages by weight, based on the total weight of the composition or article referred to. For example, a plastisol composition comprising 50.0% filler, refers to 50.0 wt% filler based on the total weight of the plastisol composition. On the other hand, a floor covering comprising 50.0% filler, refers to 50.0 wt% filler based on the total weight of the floor covering, including all layers.

[0078] The terms described above, and others used in the specification are well understood to those skilled in the art.

[0079] 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.

[0080] 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.

[0081] 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.

[0082] In a first aspect, the invention relates to a multilayer floor covering comprising in following order: a backing layer, a coating layer based on a polymer-in-water dispersion, and a wear layer, wherein the backing layer, the coating layer, and the wear layer each comprise a thermoplastic polymer wherein said thermoplastic polymer in each layer is of the same family of thermoplastic polymers; wherein the backing layer, the coating layer and the wear layer are essentially free of PVC homopolymers and PVC copolymers, and wherein the backing layer has an air permeability of at least 500 l / m2 / s, measured at 200 Pascal according to ISO 9237. Preferably, the backing layer, the coating layer and the wear layer are free of PVC homopolymers and PVC copolymers. In some preferred embodiments, the backing layer, the coating layer, and the wear layer are essentially free of any polymer other than the thermoplastic polymer that is present in said layers. Preferably, the backing layer, the coating layer and the wear layer are free of any polymer other than the thermoplastic polymer. In some preferred embodiments, the backing layer, the coating layer, and the wear layer only comprise the thermoplastic polymer as a polymer. In some preferred embodiments, the thermoplastic polymer in the backing layer, the coating layer and the wear layer is identical.

[0083] In some preferred embodiments, the floor covering as disclosed herein is essentially free of PVC homopolymers and PVC copolymers; preferably free of PVC homopolymers and PVC copolymers. In some embodiments, the multilayer floor covering is essentially free of any polymer other than the identical polymer; preferably free of any polymer other than the identical polymer. In some embodiments, the multilayer floor covering thus comprises only one type of thermoplastic polymer.

[0084] In some preferred embodiments, the backing layer, the coating layer and the wear layer are essentially free of plasticizers. In some embodiments, the backing layer, the coating layer and the wear layer are thus essentially free of PVC homopolymers, PVC copolymers and plasticizers. In some embodiments, the backing layer, the coating layer and the wear layer are free of plasticizers. In some embodiments, the backing layer, the coating layer and the wear layer are thus free of PVC homopolymers, PVC copolymers and plasticizers.

[0085] In some preferred embodiments, the floor covering as disclosed herein is essentially free of plasticizers. In some embodiments, the floor covering as disclosed herein is thus essentially free of PVC homopolymers, PVC copolymers and plasticizers. In some embodiments, the floor covering as disclosed herein is free of plasticizers. In some embodiments, the floor covering as disclosed herein is thus free of PVC homopolymers, PVC copolymers and plasticizers.

[0086] As used herein, the term “essentially free of” of a substance or compound means that the substance or compound is only present in trace amounts that do not affect the overall properties or performance of the product. For example, essentially free of PVC or essentially free of PVC homopolymers and PVC copolymers means that PVC homopolymers and PVC copolymers are only present in trace amounts. Or, essentially free of any polymer other than the thermoplastic polymer of the same family means that other polymers than the thermoplastic polymers from that specific family are only present in trace amounts. In some embodiments, essentially free of PVC homopolymers and PVC copolymers means that at most 5.0 wt% PVC homopolymers, at most 5.0 wt% PVC copolymers, or at most 5.0wt% of a combination of PVC homopolymers and PVC copolymers are present in a layer or in the floor covering as disclosed herein. In some further embodiments, essentially free of PVC homopolymers and PVC copolymers means that at most 1.0 wt%, preferably at most 0.50 wt%, or preferably at most 0.10 wt%; more preferably at most 0.050 wt%; even more preferably at most 0.01 wt% PVC homopolymers; at most 1.0 wt%, preferably at most 0.50 wt%, or preferably at most 0.10 wt%; more preferably at most 0.050 wt%; even more preferably at most 0.010 wt% PVC copolymers; or at most 1.0 wt%, preferably 0.50 wt%, or preferably at most 0.10 wt%; more preferably at most 0.050 wt%; even more preferably at most 0.010 wt% of a combination of PVC homopolymers and PVC copolymers are present in a layer or in the floor covering as disclosed herein.

[0087] In some embodiments, essentially free of any polymer other than the thermoplastic polymer of the same family means that at most 5.0 wt% of any polymer other than the thermoplastic polymer of the same family is present in a layer or in the floor covering as disclosed herein. In some further embodiments, essentially free of any polymer other than the identical thermoplastic polymer means that at most 1.0 wt%, preferably at most 0.50 wt%, or preferably at most 0.10 wt%; more preferably at most 0.050 wt%; even more preferably at most 0.010 wt% of any polymer other than the identical thermoplastic polymer is present in a layer or in the floor covering as disclosed herein.

[0088] In some embodiments, essentially free of plasticizers means that plasticizers are only present in trace amounts. In some embodiments, essentially free of plasticizers means that at most 5.0 wt% plasticizer, or at most 5.0 wt% of a combination of one or more plasticizers are present in a layer or in the floor covering as disclosed herein. In some further embodiments, essentially free of plasticizers means that at most 1.0 wt%, preferably at most 0.50 wt%, preferably at most 0.10 wt%; more preferably at most 0.050 wt%; even more preferably at most 0.010 wt% of a plasticizer or that at most 1.0 wt%, preferably at most 0.50 wt%, or preferably at most 0.10 wt%; more preferably at most 0.050 wt%; even more preferably at most 0.010 wt% of a combination of plasticizers; are present in a layer or in the floor covering as disclosed herein. With the term “plasticizer” as used herein, a compound is meant that typically can increase the fluidity or plasticity of a material, typical a polymer. The plasticizer can be any conventional plasticizer known in the art. For example, the plasticizer may be a phthalic diester (also known as “phthalates), such as diisonyl phthalate, diallyl phthalate, di-2-ethylhexyl phthalate, dioctyl phthalate, and diisodecyl phthalate.

[0089] In some preferred embodiments, the backing layer, the coating layer, and the wear layer are free of PVC homopolymers and PVC copolymers. In some preferred embodiments, the backing layer, the coating layer, and the wear layer do not comprise any other polymer than the thermoplastic polymer that is of the same family of thermoplastic polymers . As such, only one type of polymer family is present in the backing layer, the wear layer, and the coating layer which improves the recycling capacity of the floor covering. The backing layer, the coating layer, and the wear layer may thus comprise only the thermoplastic polymer as a polymer. In some embodiments, the floor covering as disclosed herein is free of PVC homopolymers and PVC copolymers. In some embodiments, the multilayer floor covering is free of any polymer other than the thermoplastic polymer that is of the same family of thermoplastic polymers. The multilayer floor covering as disclosed may thus not comprise any other polymer than the thermoplastic polymer that is of the same family of thermoplastic polymers. As such, only one type of thermoplastic polymer family may be present in the floor covering as disclosed herein.

[0090] In some further preferred embodiments, the backing layer, the coating layer, and the wear layer are free of plasticizers. In some further embodiments, the backing layer, the coating layer, and the wear layer do not comprise any type of plasticizer.

[0091] In some further preferred embodiments, the floor covering as disclosed herein is free of plasticizers. The multilayer floor covering as disclosed may thus not comprise any type of plasticizer.

[0092] As used herein, the term “free of” a substance or compound means that said substance or compound is not present in the product. This implies a complete absence of the substance or compound in the product, where analytical techniques or methods would not detect the presence of the substance or compound within the limits of detection. For example, the term “free of PVC”, or “free of PVC homopolymers and PVC copolymers” means that no PVC, in particular no PVC homopolymers and PVC copolymers, are present in the layers or product as disclosed herein. Or, free of any polymer other than the identical polymer means that other polymers than the identical polymer are not present in the layers or product as disclosed herein. Or, free of any plasticizer, means that no plasticizer is present in the layers or product as disclosed herein.

[0093] The floor covering of the present invention is thus preferably characterized in that the backing layer, the coating layer, and the wear layer are essentially free of PVC homopolymers and PVC copolymer but that each of these three layers comprises a thermoplastic polymer, wherein said thermoplastic polymer in each of the layers is of the same family of thermoplastic polymers. In some preferred embodiments, the whole multilayer floor covering is essentially free of PVC homopolymers and PVC copolymers.

[0094] In some preferred embodiments, the backing layer, the coating layer, and the wear layer are free of PVC homopolymers and PVC copolymer but each of these three layers comprises a thermoplastic polymer that is of the same family of thermoplastic polymers. In some preferred embodiments, the whole multilayer floor covering is free of PVC homopolymers and PVC copolymers. As used herein, the term “thermoplastic polymer” refers to a polymer that becomes pliable or mouldable upon heating and solidifies upon cooling. Thermoplastic polymers are characterized by their ability to soften when exposed to heat and to harden when cooled.

[0095] The thermoplastic polymer in the backing layer, the coating layer, and the wear layer of the floor covering described herein can be any thermoplastic polymer except a PVC homopolymer and PVC copolymer. In some embodiments, a thermoplastic polymer can also be present in any of the other layers of the floor covering.

[0096] The wear layer, coating layer and backing layer of the floor covering disclosed herein thus each comprise a thermoplastic polymer, wherein said thermoplastic polymer in each of the layers belongs to the same family of thermoplastic polymers.

[0097] As used herein, the term “family of thermoplastic polymers” refers to the different families of thermoplastic polymers that are available. The different families of thermoplastic polymers include polyolefins, vinyl polymers, polystyrenes, acrylics, polyamides, polyesters, polycarbonates, acetal polymers, fluoropolymers, polyurethanes and polyimides. The wording “same family of thermoplastic polymers” refers to a single family of thermoplastic polymers. As such, the thermoplastic polymer present in each of the wear layer, coating layer and backing layer is a thermoplastic polymer that belongs to the same family of polymers but can still be a different type of polymer within that same family or a copolymer of different polymers within that same family.

[0098] In some preferred embodiments, the thermoplastic polymer in the wear layer, the coating layer and the backing layer of the floor covering as disclosed herein is identical in each layer. In some further preferred embodiments, the thermoplastic polymer in the wear layer, the coating layer, the backing layer and any additional layer present in the floor covering as disclosed herein is identical.

[0099] In some embodiments, the thermoplastic polymer is a polymer selected from the family of polyolefins, polystyrenes, polyamides, or polyesters; preferably from the family of thermoplastic polymers selected from polyolefins, polyesters or polyamides.

[0100] In some embodiments, the thermoplastic polymer family is the family of polyolefins. In some embodiments, the thermoplastic polymer family is the family of polystyrenes. In some embodiments, the thermoplastic polymer family is the family of polyamides. In some embodiments, the thermoplastic polymer family is the family of polyesters.

[0101] As used herein, a family of thermoplastic polymers is a group of thermoplastic polymers that share a common chemical structure, synthesis pathway or other characteristics. In preferred embodiments, members within a family of polymers are derived from the same type of monomer or closely related monomers.

[0102] In some further embodiments, the thermoplastic polymer is selected from the group consisting of polyethylene (PE), polypropylene (PP), polybutene (PB), polyisobutylene (PIB), ethylene vinyl acetate (EVA), ethylene-propylene copolymer, ethylene-butene copolymer, ethyleneoctene copolymer, butadiene-propylene copolymer, styrene-butadiene copolymer, styrenepropylene copolymer, styrene-acrylonitrile copolymer, styrene-methyl methacrylate copolymer, polycaprolactam, polyhexamethylene adipamide, polyamide 11 , polyamide 12, polyethylene terephthalate (PET), co-PET, polyethylene terephthalate glycol (PETG), polybutylene terephthalate (PBT), polyethylene naphthalate (PEN), polylactic acid (PLA), and polycaprolactone (PCL). More preferably, the thermoplastic polymer is selected from the group consisting of polyethylene (PE), polypropylene (PP), ethylene-propylene copolymer, ethylene-butene copolymer, ethylene-octene copolymer, polyethylene terephthalate glycol, polybutylene terephthalate, polyethylene terephthalate (PET), and co-PET.

[0103] In some embodiments, the thermoplastic polymer is a polymer of the family of polyolefins. As used herein, polyolefins are to be understood as any homo- or copolymer made from monomers such as ethylene or propylene by a polymerisation process into a linear or branched configuration resulting in low-density or high-density polymer structure or any structure in between low-density or high-density. Polyolefin copolymers can be random copolymers, block polymers, alternating copolymers, graft copolymers, or gradient copolymers. Polyolefins can also include a mixture of homopolymers and copolymers. In some preferred embodiments, the thermoplastic polymer is selected from the group consisting of polypropylene (PP), polyethylene (PE), polypropylene (PP), polybutene (PB), polyisobutylene (PIB), butadiene-propylene copolymer, ethylene-propylene copolymer, ethylene-butene copolymer, or ethylene-octene copolymer. Preferably, the thermoplastic polymer is PP, ethylene-propylene copolymer, ethylene-butene copolymer, or ethylene-octene copolymer. More preferably, the thermoplastic polymer is PP.

[0104] In some embodiments, the thermoplastic polymer is ethylene vinyl acetate (EVA) or ethylene methyl acetate (EMA).

[0105] In some embodiments, the thermoplastic polymer is a polymer of the family of polystyrenes. In some preferred embodiments, the thermoplastic polymer is selected from the group consisting of styrene-butadiene copolymer, styrene-propylene copolymer, styrene-acrylonitrile copolymer, styrene-methyl methacrylate copolymer.

[0106] In some embodiments, the thermoplastic polymer is a polymer of the family of polyamides. In some preferred embodiments, the thermoplastic polymer is selected from the group consisting of polycaprolactam (nylon 6), polyhexamethylene adipamide (nylon 6,6), polyamide 11 (nylon 11), and polyamide 12 (nylon 12).

[0107] In some embodiments, the thermoplastic polymer is a polymer of the family of polyesters

[0108] (PES). Polyester (PES) refers to a category of polymers that are combinations of diacids and diols and contain ester linkages in every repeat unit of their main chain. Combinations of different diacids and diols result in different types of polyesters. Typically, polyesters consisting of only one type of diacid and diol are called polyester whereas polyesters consisting of multiple types of diacid and / or diol are called coPET. Polyethylene terephthalate (PET), which is a combination of diacid terephthalic acid (or dimethyl terephthalate) and diol ethylene glycol, is a specific type of polyester included in this family. In some preferred embodiments, the thermoplastic polymer is selected from the group consisting of polyethylene terephthalate

[0109] (PET), co-PET, polyethylene terephthalate glycol (PETG), polybutylene terephthalate (PBT), polyethylene naphthalate (PEN), polylactic acid (PLA), polycaprolactone (PCL). In some more preferred embodiments, the thermoplastic polymer is PET or a co-PET.

[0110] The thermoplastic polymers present in the wear layer, coating layer and backing layer are part of the same family of thermoplastic polymers but they can still be different in each layer. For example, the thermoplastic polymer in each of the layers, preferably in the whole floor covering, may belong to the family of polyolefins, but the thermoplastic polymer in the wear layer can be polypropylene (PP), whereas the thermoplastic polymer in the coating layer and backing layer is polyethylene (PE). Or, the thermoplastic polymer can be a polypropylene (PP), with a type 1 PP present in one layer and a type 2 PP present in another layer. For example, the thermoplastic polymer can be a PP, but still include both a type 1 PP and a type 2 PP. Hence, in the multilayer floor covering according to the invention, the backing layer can comprise one type of a polymer of the same family, e.g. type 1 PP, whereas the coating layer and / or the wear layer can comprise another type of the polymer of the same family, e.g. type 2 PP.

[0111] Some thermoplastic polymers indeed comprise different types of polymers that still belong to the same family. For example, PP is a polymer family comprising different types categorized based on their structure and properties. Type 1 PP, also known as PP homopolymer, is the most basic form of PP made from polymerizing only propylene monomers. Type 2 PP, also known as PP copolymer, is produced by the copolymerization of propylene and ethylene monomers (typically less than 6%). Type 3 PP, also known as PP impact polymer or block copolymer polypropylene, is made by polymerizing PP with a higher percentage of ethylene (up to 15%). Type 4 PP, also known as expanded PP, is a foam form of PP produced by heating and melting, thereby expanding, PP beads. Type 5 PP, also known as PP terpolymer, is produced by polymerization of three monomers propylene, ethylene and a third monomer such as butene or hexene. Type 6 PP, also known as high melt strength PP, is produced by incorporating a specific amount of long chain branching into the PP polymer chain during the polymerization process. As a result, a modified PP with enhanced melt strength and elasticity is created.

[0112] In some preferred embodiments, the identical polymer can be selected from the group consisting of type 1 PP, type 2 PP, and type 3 PP. As such, in a multilayer floor covering according to an embodiment of the invention, the backing layer, the coating layer, and the wear layer may comprise a type 1 PP, a type 2 PP, a type 2 PP, or a mixture thereof.

[0113] In some embodiments, the thermoplastic polymer can be a mixture of two or more thermoplastic polymers that belong to the same family of thermoplastic polymers. In some embodiments, the thermoplastic polymer can be a copolymer of two thermoplastic polymers that belong to the same family of thermoplastic polymers.

[0114] In some embodiments, the thermoplastic polymer is a mixture of two or more polyolefins, such as for example a mixture of PP and PE. In some embodiments, the thermoplastic polymer is a copolymer, such as ethylene-propylene copolymer, ethylene-butene copolymer, or ethyleneoctene copolymer.

[0115] The thermoplastic polymer as used herein can be a virgin thermoplastic polymer, a recycled thermoplastic polymer, or a mixture thereof. In some embodiments the thermoplastic polymer is a recycled thermoplastic polymer. As used herein, “recycled” thermoplastic polymer refers to a thermoplastic polymer that is prepared by processing polymer waste products, such as thermoplastic polymers derived from domestic waste, household waste, or end of life products waste. In some embodiments, the origin of the recycled thermoplastic polymer is postindustrial waste, pre-consumer waste (before or after installation), post-consumer waste, flooring waste, waste from cables or window profiles. In some embodiments, washing and grinding operations can be used for processing post-consumer items into recycled thermoplastic polymers to be used in the product or method of the invention.

[0116] The backing layer, the coating layer, and the wear layer of the floor covering as described herein will thus comprise only thermoplastic polymers that belong to the same family. In some preferred embodiments, the floor covering as described herein comprises only thermoplastic polymers that belong to the same family.

[0117] Also preferable for the invention is that the backing layer, the coating layer, and the wear layer are essentially free of PVC, in particular essentially free of PVC homopolymers and PVC copolymers, more in particular free of PVC homopolymers and PVC copolymers. In some further embodiments, also other layers, if present, of the floor covering are essentially free of PVC homopolymers and PVC copolymers, in particular free of PVC homopolymers and PVC copolymers.

[0118] In still some further preferred embodiments, the multilayer floor covering is essentially free of PVC homopolymers and PVC copolymers, in particular free of PVC homopolymers and PVC copolymers.

[0119] The absence of PVC in at least the backing layer, the coating layer, and the wear layer, and preferably in the complete floor covering, thus eliminates the environmental and health concerns associated with PVC.

[0120] Further preferred is that the backing layer, the coating layer, and the wear layer are essentially free of plasticizers, more in particular free of plasticizers.

[0121] In some further embodiments, also other layers, if present, of the floor covering are essentially free of plasticizers, in particular free of plasticizers.

[0122] In still some further preferred embodiments, the multilayer floor covering is essentially free of plasticizers, in particular free of plasticizers.

[0123] The absence of plasticizers, in addition to the absence of PVC, in at least the backing layer, the coating layer, and the wear layer, and preferably in the complete floor covering, also eliminates the environmental and health concerns associated with plasticizers. Advantageously and even in the absence of PVC, and optionally also in the absence of plasticizers, the floor covering disclosed herein still comprises good bending properties, as reflected by the bending stiffness, and thus a flexible floor covering is still provided.

[0124] In some embodiments, the multilayer floor covering has a bending stiffness of at most 800.0 N.mm as measured according to the bending stiffness test disclosed herein, in particular as measured using a modified bending stiffness test according to ISO 5628. As such, the multilayer floor covering is a flexible floor covering. In some preferred embodiments, the multilayer floor covering has a bending stiffness of at most 600 N.mm, preferably at most 450 N.mm, more preferably at most 350 N.mm, as measured according to the bending stiffness test disclosed herein, in particular as measured using a modified bending stiffness test according to ISO 5628.

[0125] In some embodiments, the multilayer floor covering has a bending stiffness of at least 5.0 N.mm as measured according to the bending stiffness test disclosed herein. In some preferred embodiments, the multilayer floor covering has a bending stiffness of at least 100.0 N.mm, preferably at least 150.0 N.mm, more preferably at least 180.0 N.mm, as measured according to the bending stiffness test disclosed herein, in particular as measured using a modified bending stiffness test according to ISO 5628.

[0126] In some embodiments, the multilayer floor covering has a bending stiffness of at least 5.0 N.mm and at most 800 N.mm as measured according to the bending stiffness test disclosed herein. Preferably, the bending stiffness is of at least 100.0 N.mm and at most 600 N.mm, more preferably of at least 150.0 N.mm to at most 450 N.mm, even more preferably at least 180.0 N.mm to at most 350.0 N.mm, as measured according to the bending stiffness test disclosed herein.

[0127] The term “bending stiffness” as used herein is defined as the force (in Newton. millimeter, N.mm; or similarly in milliNewton. meter, mN.m) that is required to bend a rectangular test piece to a specified angle (for example an angle of 30°), when the test piece is fixed at one end and the force is applied to its free end.

[0128] In some embodiments, the bending stiffness test as disclosed herein is a modified bending stiffness test based on the bending stiffness test according to ISO 5628. The bending stiffness test according to ISO 5628 is a bending stiffness test for paper and board. In the present application, for application in the field of floor covering products as disclosed herein, the bending stiffness test has been slightly modified. In particular, the bending stiffness test as disclosed herein is according to ISO 5628 but the measurement of the bending stiffness is performed at an angle of 30°. In some embodiments, the bending stiffness as disclosed herein is thus measured using a modified bending test according to ISO 5628 wherein the bending angle is set at 30°. Thus, in some embodiments, the bending force F that needs to be applied to reach a bending angle of 30° for a sample of a particular size is then determined using a Bending Tester system and the bending stiffness can be calculated based on Formula (I).

[0129] In some embodiments, bending stiffness (Sb) is calculated using the following Formula (I):

[0130] Sb = (60 x F x L2) / (TT x a x w) (Formula I) wherein

[0131] Sb = bending stiffness (N.mm)

[0132] F = bending force (N)

[0133] L = sample length (mm) a = bending angle (°) w = sample width (mm) For example, the bending stiffness test can be performed using a Bending Tester available in the prior art, and wherein a test sample is placed in a clamp, such as for example a L&W Bending Tester.

[0134] The multilayer floor covering described herein comprises a backing layer on which a coating is applied. The multilayer floor covering as disclosed herein comprises a backing layer that is essentially free of PVC, in particular essentially free of PVC homopolymers and PVC copolymers; more preferably free of PVC homopolymers and PVC copolymers. The backing layer still comprises a thermoplastic polymer, a thermoplastic polymer that is of the same family of thermoplastic polymers as the polymer present in the coating layer and the wear layer, but said polymer is not PVC. The thermoplastic polymer in the backing layer is preferably a thermoplastic polymer selected from the group consisting of polyolefins (including olefin copolymers), polystyrenes, polyamides (including co-polyamides), and polyesters (including co- polyesters).

[0135] The backing layer as used herein can be any material as long as the air permeability of the material is high enough to allow heat penetration into the backing layer so that evaporation of water after application of the coating layer based on a polymer- in-water can occur such that the different layers can be fused in a robust manner.

[0136] Thus, in order to allow sufficient water evaporation from the coating layer it is particularly preferred that the backing layer has a high air permeability such that water from the polymer- in-water dispersion of the coating can be easily evaporated after application of the coating on the backing layer such that the layers can be fused in a robust manner. The air permeability of the backing layer is thereof at least 500 l / m2 / s at 200 Pascal, measured according to ISO 9237. In preferred embodiments, the air permeability of the backing layer is at least 750 l / m2 / s or at least 1000 l / m2 / s, more preferably at least 1250 l / m2 / s, at 200 Pascal, measured according to ISO 9237.

[0137] In some embodiments, the backing layer has a wet strength (also referred to as wet tensile strength) of at least 30.0 %, preferably at least 40.0 %, more preferably at least 50.0% and even more preferably at least 60.0%, of the breaking strength at the temperature at which the floor covering is heated during manufacture. In some embodiments, the wet strength is measured according to ISO 1421 :2017 (section 8.1).

[0138] In some embodiments, the backing layer comprises at least 80.0 wt%, preferably at least 85.0 wt%, more preferably at least 90.0 wt%, of the thermoplastic polymer, based on the total weight of the backing layer. In some preferred embodiments, the backing layer comprises at least 95.0 wt% of the thermoplastic polymer, such as for example 95.0 wt%; 96.0 wt%, 97.0 wt%, 98 wt%, 99 wt% or even 100 wt%, of the thermoplastic polymer, based on the total weight of the backing layer.

[0139] In some embodiments, the backing layer only comprises one thermoplastic polymer, such as one polymer selected from polypropylene (PP), polyethylene (PE), polybutene (PB), polyisobutylene (PIB), ethylene vinyl acetate (EVA), butadiene-propylene copolymer, ethylene-propylene copolymer, ethylene-butene copolymer, ethylene-octene copolymer, styrene-butadiene copolymer, styrene-propylene copolymer, styrene-acrylonitrile copolymer, styrene-methyl methacrylate copolymer, polycaprolactam (nylon 6), polyhexamethylene adipamide (nylon 6,6), polyamide 11 (nylon 11), polyamide 12 (nylon 12), polyethylene terephthalate (PET), co-PET, polyethylene terephthalate glycol (PETG), polybutylene terephthalate (PBT), polyethylene naphthalate (PEN), polylactic acid (PLA), and polycaprolactone (PCL), and no other polymers are present in the backing layer. In some embodiments, the backing comprises only PP, PE ethylene-propylene copolymer, ethylenebutene copolymer, ethylene-octene copolymer, PET, or co-PET, and no other polymers. In some embodiments, the backing layer is thus a mono- or co-polymer material backing layer wherein only one type of thermoplastic polymer is present.

[0140] The term “backing layer”, “backing sheet”, or “backing film” refers to a layer that may be used as a backing.

[0141] In some embodiments, the backing layer is a textile layer, such as a woven or non-woven layer including a felt, a fibrous layer wherein the fibre can be a natural fibre, such as jute or flaw, or a mineral fibre such as glass fiber.

[0142] As sued herein, the terms “fiber” or “fibre” and “filament” refer to filamentous material that can be used in yarn fabric and non-woven textile fabrication.

[0143] The term “non-woven” which can be used with the present invention may be staple non-woven made by providing cut fibers of a few centimeters length, putting these into bales, placing on a conveyer belt and dispersed, e.g. spread in a uniform web by a wetlaid, airlaid, or carding / crosslapping process.

[0144] In some embodiments, the backing layer comprises a glass fiber layer. After all, the presence of a glass fiber layer will not affect the recycling ability of the thermoplastic polymer material in the backing layer as long as the content of the fiberglass in the backing layer is below 40 g / m2.

[0145] In some embodiments, the backing layer is a non-woven backing layer; preferably a nonwoven textile backing layer or a non-woven polyester layer, such as needle felt or continuous web. The backing layer may comprise additional sublayers as a back print. As used herein the term “non-woven” refers to a sheet of fibres, continuous filaments, or chopped yarns of any nature or origin, that have been formed into a web of any means, and bonded together by any means, with the exception of weaving or knitting. Composite structure may be considered nonwoven provided their mass is constituted of at least 50% of non-woven as per to the above definition, or if the non-woven component plays a relevant role.

[0146] The non-woven backing layer as used herein can be a spun-laid non-woven backing layer, a spunbonded non-woven backing layer, a needle-felt non-woven backing layer, or an airlaid non-woven backing layer.

[0147] In some embodiments, the backing layer is a woven backing layer.

[0148] In some embodiments, and in particular when a reinforcement layer comprising glass fiber tissue is present, an additional coating layer is applied on the backing layer. The additional coating layer is based on a polymer-in-water dispersion comprising a thermoplastic polymer that is of the same family of thermoplastic polymers as the polymer of the wear layer, coating layer and backing layer. In some preferred embodiments, the polymer in the additional coating layer is identical to the polymer in the coating layer.

[0149] The backing layer may further comprise a foamed layer, for instance for improving acoustics or providing thermal insulation.

[0150] The backing layer as used herein can be any material as long as the air permeability of the material is high enough to allow heat penetration into the backing layer so that evaporation of water after application of the coating layer can occur.

[0151] Thus, in order to allow sufficient water evaporation from the coating layer it is particularly preferred that the backing layer has a high air permeability such that water from the polymer- in-water dispersion of the coating can be easily evaporated after application of the coating on the backing layer. In some preferred embodiments, the air permeability of the backing layer is at least 750 l / m2 / s or at least 1000 l / m2 / s, more preferably at least 1250 l / m2 / s, at 200 Pascal, measured according to ISO 9237.

[0152] In some embodiments, the backing layer has an area weight of at least 50.0 g / m2and at most 3000.0 g / m2; preferably of at least 80.0 g / m2to at most 2000.0 g / m2, more preferably of at least 85.0 g / m2to at most 1000.0 g / m2, or of at least 100.0 g / m2to at most 700.0 g / m2, as measured according to ISO EN 29073-1.

[0153] As used herein, the area weight of a layer, such as the backing layer, refers to the mass per unit area of the material and is typically expressed in g / m2according to ISO EN 29073-1 . The floor covering of the invention preferably comprises a coating layer based on a polymer- in-water dispersion that is applied to the backing layer.

[0154] In some embodiments, the coating layer has a thickness of at least 0.10 mm; preferably at least 0.20 mm; more preferably at least 0.25 mm.

[0155] In some embodiments, the coating layer has a thickness of at least 0.10 mm and at most 5.0 mm. In some embodiments, the coating layer has a thickness of at least 0.10 mm and at most 2.0 mm; preferably at least 0.20 mm and at most 2.0 mm; more preferably at least 0.20 mm and at most 1.50 mm; even more preferably at least 0.20 mm and at most 1.00 mm. For example, the coating layer may have a thickness of about 0.25 mm, about 0.30 mm, about 0.50 mm, about 0.70 mm, about 1.00 mm, or about 1.50 mm.

[0156] In some embodiments, the thickness of the coating layer is measured according to EN ISO24340.

[0157] In some embodiments, the floor covering disclosed herein comprises an additional coating layer, also referred to as a second coating layer. Said additional coating layer is also based on a polymer-in-water dispersion.

[0158] In some embodiments, the additional coating layer has a thickness of at least 0.10 mm; preferably at least 0.20 mm; more preferably at least 0.25 mm.

[0159] In some embodiments, the additional coating layer has a thickness of at least 0.10 mm and at most 5.0 mm. In some embodiments, the additional coating layer has a thickness of at least 0.10 mm and at most 2.0 mm; preferably at least 0.20 mm and at most 2.0 mm; more preferably at least 0.20 mm and at most 1.50 mm; even more preferably at least 0.20 mm and at most 1.00 mm. For example, the additional coating layer may have a thickness of about 0.25 mm, about 0.30 mm, about 0.50 mm, about 0.70 mm, about 1.00 mm, or about 1.50 mm. In some embodiments, the thickness of the additional coating layer is measured according to EN ISO24340.

[0160] As used herein, a polymer-in-water dispersion is a colloidal system in which polymer particles are dispersed in water.

[0161] In some embodiments, the coating layer and / or additional coating layer is only a single coating layer based on a polymer-in-water dispersion.

[0162] In some embodiments, the coating layer and / or additional coating layer may comprise a first coating layer based on a polymer-in-water dispersion and a second coating layer based on a polymer-in-water dispersion. In some embodiments, the coating layer and / or additional coating layer may comprise a first coating layer and a second coating layer that are distinguishable. In some embodiments, the coating layer and / or additional coating layer may comprise a first coating layer and a second coating layer that are indistinguishable.

[0163] When a coating layer and an additional coating layer are present in the floor covering, both the coating layer and the additional coating layer are each based on a polymer-in-water dispersion. When an additional coating layer is present in the floor covering, the additional coating layer is also based on a polymer-in-water dispersion.

[0164] In some embodiments, the coating layer and the additional coating layer are identical. In some embodiments, the coating layer and the additional coating layer are different and based on a different polymer-in water dispersion but wherein the thermoplastic polymer in the coating layer and additional coating layer is of the same family of thermoplastic polymers. In some embodiments, the polymer-in-water dispersion of the coating layer and of the additional coating layer has the same composition. In some embodiments, the polymer-in-water dispersion of the coating layer and of the additional coating layer has a different composition but the coating layer and the additional coating layer still comprise a thermoplastic polymer that is of the same family of thermoplastic polymers.

[0165] In some embodiments, the polymer-in-water dispersion of the coating layer and the additional coating layer has the same composition. In some embodiments, the polymer-in-water dispersion of the coating layer and the additional coating layer has a different composition but the coating layer and the additional coating layer comprise a thermoplastic polymer that is of the same family of thermoplastic polymers.

[0166] In some embodiments, and when an additional coating layer is present, the backing layer, the coating layer, the additional coating layer and the wear layer each comprise a thermoplastic polymer that is of the same family of polymers or copolymers, preferably an identical thermoplastic polymer. In some embodiments, the backing layer, the coating layer, the additional coating layer, and the wear layer are essentially free of any polymer other than the thermoplastic polymer. In still some further embodiments, the backing layer, the coating layer, the additional coating layer, and the wear layer are free of any polymer other than the thermoplastic polymer.

[0167] In some embodiments, the coating layer, and optionally the additional coating layer, comprises one thermoplastic polymer, preferably one polymer that is of the family of polyolefins (including olefin copolymers), polystyrenes, polyamides (including co-polyamides), and polyesters (including co-polyesters), more preferably selected from the group consisting of polypropylene (PP), polyethylene (PE), polybutene (PB), polyisobutylene (PIB), ethylene vinyl acetate (EVA), butadiene-propylene copolymer, ethylene-propylene copolymer, ethylene-butene copolymer, styrene-butadiene copolymer, styrene-propylene copolymer, styrene-acrylonitrile copolymer, styrene-methyl methacrylate copolymer, polycaprolactam (nylon 6), polyhexamethylene adipamide (nylon 6,6), polyamide 11 (nylon 11), polyamide 12 (nylon 12), polyethylene terephthalate (PET), co-PET, polyethylene terephthalate glycol (PETG), polybutylene terephthalate (PBT), polyethylene naphthalate (PEN), polylactic acid (PLA), and polycaprolactone (PCL), and no other polymers are present in the coating layer. In some embodiments, the coating layer, and optionally the additional coating layer, comprises only PP, PE, co-PET, ethylene-propylene copolymer, ethylene-butene copolymer, ethylene-octene copolymer, or PET and no other polymers. In some embodiments, the coating layer, and optionally the additional coating layer, is thus a mono-polymer or co-polymer material coating layer wherein only one type of thermoplastic polymer family is present, preferably wherein only one type of thermoplastic polymer is present.

[0168] In some embodiments, the polymer-in-water dispersion of the coating layer, and optionally the additional coating layer, comprises at least 10.0 wt% thermoplastic polymer based on the total weight of the polymer-in-water dispersion. In some embodiments, the polymer-in-water dispersion comprises at most 90.0 wt% thermoplastic polymer based on the total weight of the polymer-in-water dispersion. In some embodiments the polymer-in-water dispersion comprises at least 20.0 wt% and at most 90.0 wt% of the thermoplastic polymer, preferably at least 20.0 wt% and at most 80.0 wt%, more preferably at least 25.0 wt% and at most 80.0 wt%, or at least 30.0 wt% and at most 75.0 wt%, such as for example 35.0 wt% or 55.0 wt%, of the thermoplastic polymer based on the total weight of the polymer-in-water dispersion.

[0169] In some embodiments, the amount of polymer in the polymer-in-water dispersion of the coating layer and the additional coating layer is the same. In some embodiments, the amount of polymer in the polymer-in-water dispersion of the coating layer and the additional coating layer is different.

[0170] In some embodiments, the amount of polymer in the polymer-in-water dispersion of the first coating layer and the second coating layer is the same. In some embodiments, the amount of polymer in the polymer-in-water dispersion of the first coating layer and the second coating layer is different.

[0171] It should be understood that after application of the coating layer, the large majority of the water in the polymer-in-water dispersion will evaporate, such that the water content in the coating layer will finally be below 10.0 wt%; preferably below 5.0 wt%. In some embodiments, the polymer-in-water dispersion comprises a thermoplastic polymer and one or more additives, such as inorganic fillers. Preferably, the inorganic fillers are selected from the group consisting of talcum, calcium carbonate, chalk, wollastonite, mica, or a combination thereof. In some embodiments, the filler is calcium carbonate. In some further embodiments, when the thermoplastic polymer in the coating layer is a polyolefin, the filler is calcium carbonate. In some embodiments, the coating layer thus comprises of a polyolefin and calcium carbonate.

[0172] In some embodiments, the polymer-in-water dispersion further comprises a thickener, a dispersant, a foaming agent, an adhesion promoter, a wetting agent, a colorant or a pigment, or a mixture thereof.

[0173] In some preferred embodiments, the polymer-in-water dispersion may further comprise one or more colorants or pigments. As a result, the coating layer can comprise a specific color, a specific design, or a variegated pattern. In some embodiments, and when the coating layer comprises one or more colorants or pigments, it will not be necessary to apply a specific print pattern to the surface of the wear layer. In some embodiments, the coating layer comprises a variegated pattern. As used herein a variegated pattern refers to a irregular pattern, such as a pattern in the form of different flames, wherein said irregular pattern is created by the presence of non-uniform dispersed pigment in the coating layer.

[0174] In some embodiments, the polymer-in-water dispersion comprises at least 0.5 wt% of one or more additives, such as inorganic fillers, based on the total weight of the polymer-in-water dispersion. In some embodiments, the polymer-in-water dispersion comprises at most 45.0 wt% of one or more additives, such as one or more inorganic fillers, based on the total weight of the polymer-in-water dispersion. In some embodiments the polymer-in-water dispersion comprises at least 0.5 wt% and at most 45.0 wt% of one or more additives, such as inorganic fillers, preferably at least 1 .0 wt% and at most 45.0 wt%, more preferably at least 1.0 wt% and at most 40.0 wt%, of one or more additives, such as inorganic fillers, based on the total weight of the polymer-in-water dispersion.

[0175] In some embodiments, the polymer-in-water dispersion comprises at least 0.5 wt% of one or more inorganic fillers, based on the total weight of the polymer-in-water dispersion. In some embodiments, the polymer-in-water dispersion comprises at most 45.0 wt% of one or more inorganic fillers, based on the total weight of the polymer-in-water dispersion. In some embodiments the polymer-in-water dispersion comprises at least 0.5 wt% and at most 45.0 wt% of one or more inorganic fillers, preferably at least 1.0 wt% and at most 45.0 wt%, more preferably at least 1.0 wt% and at most 40.0 wt%, of one or more inorganic fillers, based on the total weight of the polymer-in-water dispersion. In some embodiments, the polymer-in-water dispersion comprises at least 0.5 wt% of calcium carbonate, based on the total weight of the polymer-in-water dispersion. In some embodiments, the polymer-in-water dispersion comprises at most 45.0 wt% of calcium carbonate, based on the total weight of the polymer-in-water dispersion. In some embodiments the polymer-in-water dispersion comprises at least 0.5 wt% and at most 45.0 wt% of calcium carbonate, preferably at least 1.0 wt% and at most 45.0 wt%, more preferably at least 1.0 wt% and at most 40.0 wt%, of calcium carbonate, based on the total weight of the polymer-in-water dispersion.

[0176] In some preferred embodiments, the polymer-in-water dispersion of the coating layer, and / or the additional coating layer has a solid content of at least 10.0 wt%; preferably at least 30.0 wt%; more preferably at least 50.0 wt% or at least 60.0 wt%; even more preferably at least 68.0 wt%, based on the total weight of the polymer-in-water dispersion. In some preferred embodiments, the polymer-in-water dispersion has a solid content of at most 75.0 wt%; preferably at most 73.0 wt%; more preferably at most 72.0 wt%, based on the total weight of the polymer-in-water dispersion.

[0177] In some embodiments, the solid content in the polymer-in-water dispersion is determined by the polymer in the polymer-in-water dispersion. In some embodiments, the solid content in the polymer-in-water dispersion is determined by the polymer, one or more fillers, and any other solid material present in the dispersion.

[0178] In some embodiments, the coating layer and / or the additional coating layer is a foamed coating layer.

[0179] In some embodiments, the foamed coating layer is a mechanically foamed coating layer.

[0180] A mechanical foam, as used herein, means any foam obtained by mechanical means, for example by agitation, whipping, frothing, gas injection, i.e. without the activation of a chemical blowing agent. A benefit of the mechanical foam of a polymer-in-water dispersion is that the air introduced in the polymer-in-water dispersion of the coating layer does not complicate the subsequent processes significantly. Compressed air injected in the frothing machine preferably should not contain moisture, which is usually the case since this compressed air is normally dried. However, a limited amount of water can be beneficial. Water can help in the process of chemical foaming due to steam formation. The amount of water which can be added is 0.1-1.5%, preferably 0.3-1.0%, ideally 0.5 wt% of the total composition. Adding a limited amount of water can improve the impregnation and saturation of the porous layer and can assist in the creation of the backing layer if this is required.

[0181] In some embodiments, the coating layer and / or the additional coating layer is chemically foamed, and the polymer-in-water dispersion comprises a foaming agent; preferably a foaming agent. As used herein, the terms “foaming agent” and “blowing 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 foaming agent is preferably activated heat.

[0182] In some embodiments, the foaming agent is selected from the group comprising: azodicarbonamide (AZO), 4,4-oxy-bis(benzenesulfonylhydrazide) (OBSH), P-toluenesulfonyl- hydrazide (TSH), P-toluenesulfonylsemicarbazide (PTSS), dinitrosopentamethylenetetramine (DNPT), sodium bicarbonate, 5-phenyltetrazole (PT), or any combinations thereof; preferably the foaming agent is AZO.

[0183] In some embodiments, the coating layer and / or additional coating layer is a non-foamed coating layer. In some embodiments, the coating layer does not comprise a foaming agent.

[0184] In some embodiments, the area weight of the coating layer and / or the additional coating layer is at least 50.0 g / m2and at most 1500.0 g / m2; preferably at least 100.0 g / m2and at most 1000.0 g / m2; more preferably at least 200.0 g / m2and at most 600.0 g / m2, preferably as measured according to ISO EN 29073-1.

[0185] In some embodiments, the multilayer floor covering further comprises a reinforcement layer. In some preferred embodiments, the reinforcement layer is a non-woven layer. Preferably, the reinforcement layer may comprise glass fibre tissue, mineral particles, cellulose fibres, PET, or a mixture thereof. For example, the reinforcement layer may comprise paper or cellulose fibres, or glass fibre tissue, or a mixture of paper fibres and glass fibre tissue. In some embodiments, the reinforcement layer is a glass fibre tissue layer. In some embodiments, the reinforcement layer is a PET layer. When a reinforcement layer is present, an additional coating layer is present in the multilayer floor covering. The reinforcement layer and the additional coating layer are located in between the coating layer and the backing layer with the additional coating layer being in contact with the backing layer and the reinforcement layer being in contact with the coating layer.

[0186] In some embodiments, the reinforcement layer has a wet strength (also referred to as wet tensile strength) of at least 30.0 %, preferably at least 40.0 %, more preferably at least 50.0% and even more preferably at least 60.0%, of the breaking strength at the temperature at which the floor covering is heated during manufacture. In some embodiments, the wet strength is measured according to ISO 1421 :2017 (section 8.1). The floor covering of the invention preferably comprises a wear layer that is applied above the coating layer, said wear layer also comprising the thermoplastic polymer that is of the same family of thermoplastic polymers as the polymer of the coating layer and backing layer and being essentially free of PVC, in particular essentially free of PVC homopolymers and PVC copolymers. In some further embodiments, the wear layer is free of PVC, in particular free of PVC homopolymers and PVC copolymers.

[0187] The wear layer still comprises a thermoplastic polymer, in particular a thermoplastic polymer that is of the same family of thermoplastic polymers present in the coating layer and the backing layer, but said polymer is not PVC. The thermoplastic polymer in the wear layer is preferably of the family of polyolefins (including olefin copolymers), polystyrenes, polyamides (including co-polyamides), and polyesters (including co-polyesters), more preferably selected from the group consisting of polypropylene (PP), polyethylene (PE), polybutene (PB), polyisobutylene (PIB), ethylene vinyl acetate (EVA), butadiene-propylene copolymer, ethylene-propylene copolymer, ethylene-butene copolymer, ethylene-octene copolymer, styrene-butadiene copolymer, styrene-propylene copolymer, styrene-acrylonitrile copolymer, styrene-methyl methacrylate copolymer, polycaprolactam (nylon 6), polyhexamethylene adipamide (nylon 6,6), polyamide 11 (nylon 11), polyamide 12 (nylon 12), polyethylene terephthalate (PET), co-PET, polyethylene terephthalate glycol (PETG), polybutylene terephthalate (PBT), polyethylene naphthalate (PEN), polylactic acid (PLA), and polycaprolactone (PCL). In some further preferred embodiments, the polymer in the wear layer is PP, PE, ethylene-propylene copolymer, ethylene-butene copolymer, PET or co-PET.

[0188] In some embodiments, the wear layer comprises only one thermoplastic polymer, such as one polymer selected from polypropylene (PP), polyethylene (PE), polybutene (PB), polyisobutylene (PIB), ethylene vinyl acetate (EVA), butadiene-propylene copolymer, ethylene-propylene copolymer, ethylene-butene copolymer, ethylene-octene copolymer, styrene-butadiene copolymer, styrene-propylene copolymer, styrene-acrylonitrile copolymer, styrene-methyl methacrylate copolymer, polycaprolactam (nylon 6), polyhexamethylene adipamide (nylon 6,6), polyamide 11 (nylon 11), polyamide 12 (nylon 12), polyethylene terephthalate (PET), polyethylene terephthalate glycol (PETG), polybutylene terephthalate (PBT), polyethylene naphthalate (PEN), polylactic acid (PLA), and polycaprolactone (PCL), and no other polymers are present in the coating layer. In some embodiments, the wear layer comprises only PP, PE, ethylene-propylene copolymer, ethylene-butene copolymer, PET or co-PET, and no other polymers. In some embodiments, the wear layer is thus a mono-polymer or co-polymer material wear layer wherein only one type of thermoplastic polymer is present.

[0189] In some embodiments, the wear layer comprises at least 80.0 wt%, preferably at least 85.0 wt%, more preferably at least 90.0 wt%, of the thermoplastic polymer, based on the total weight of the wear layer. In some preferred embodiments, the wear layer comprises at least 95.0 wt% of the thermoplastic polymer, such as for example 95.0 wt%; 96.0 wt%, 97.0 wt%, 98 wt%, 99 wt% or even 100 wt%, of the thermoplastic polymer, based on the total weight of the wear layer.

[0190] In some embodiments, the area weight of the wear layer is at least 50.0 g / m2and at most 500.0 g / m2; preferably at least 50.0 g / m2and at most 200.0 g / m2; more preferably at least 70.0 g / m2and at most 100.0 g / m2, preferably as measured according to ISO EN 29073-1.

[0191] In some embodiments, the wear layer comprises a print pattern deposited on the surface of the wear layer on the side of the coating layer. Thus, in some embodiments, the print pattern is present in between the coating layer and the wear layer.

[0192] The print pattern can be printed with printing inks, e.g. by rotogravure, flexographic or digital printing, on the wear layer. In some embodiments, the print pattern is a digitally printed pattern. In some embodiments, the print pattern is a rotogravure printed pattern.

[0193] 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 the coating layer from wearing out. Lack of wear layer colour is important to obtain a design without any colour deviations and to allow the print pattern to be visible.

[0194] In a preferred embodiment, the wear layer is a transparent layer. Preferably, the wear layer is completely clear and also does not show any yellowing over-time.

[0195] In some embodiments, the wear layer is an embossed wear layer; such as a thermally embossed wear layer, a cold embossed wear layer, or an embossed wear layer generated through a casting process. In some further embodiments, the wear layer is an embossed wear layer generated through a casting process, more specific the wear layer may be made from casting a dispersion on a carrier, optionally pre-embossed. Upon drying and curing of the dispersion, a wear layer is obtained which can be used in any of the embodiments disclosed herein.

[0196] In some embodiments, the multilayer floor covering comprises a lacquer layer that is located on the wear layer. In some embodiments, the lacquer layer is thus applied onto or above the wear layer.

[0197] The lacquer layer may be seen as an additional layer that enhances scratch resistance, stain resistance , UV resistances and / or reduces gloss in the final floor covering product.

[0198] The lacquer layer may be a polyurethane or an acrylic polymeric layer. In some preferred embodiments, the lacquer layer comprises polyurethane, polyacrylate, or a mixture thereof.

[0199] In some embodiments, the lacquer layer is water-free or solvent-free, and the liquid monomers present in the lacquer layer are curved via UV curing to form a solidified lacquer layer.

[0200] In some embodiments, the lacquer layer is a water-based or solvent-based layer. In case such a water-based or solvent-based lacquer layer is present, the water or solvent present in the lacquer layer will be evaporated during or prior to curing of the lacquer layer.

[0201] In some embodiments, the lacquer layer is essentially free of PVC, in particular essentially free of PVC homopolymers and PVC copolymers; more preferably free of PVC homopolymers and PVC copolymers.

[0202] The multilayer floor covering as disclosed herein is compliant with any of the following standards (non-limitative list): EN ISO24346 (total thickness), EN ISO24340 (Determination of thickness of layers), EN IS23997 (total weight), EN ISO 23999 (dimensional stability and 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), EN ISO 23999 (dimensional stability and curling).

[0203] The multilayer floor covering as disclosed herein thus provides a floor covering wherein the use of PVC is eliminated, but with optimal mechanical properties, as well as improved insulation and / or acoustic properties.

[0204] In some embodiments, the multilayer floor covering as disclosed herein is an embossed multilayer floor covering.

[0205] The term “embossing” or “embossed” as used herein is known in the art and based on the principle that a portion of the surface material is shaped into structures both visible and non- visible to the human eye. “Mechanical embossing” as used herein is known in the art and based on the principle that a portion of the surface of material is shaped by means of a so- called embossing mould.

[0206] In some preferred embodiments, at least the wear layer is embossed, preferably mechanically embossed. In some preferred embodiments, the wear layer and the lacquer layer are embossed, in particular wherein the relief pattern is applied to both these layers. In some other embodiments, the backing layer, the coating layer, the wear layer, and optionally the lacquer layer, are embossed; preferably mechanically embossed. In some embodiments, the total thickness of the multilayer floor covering is in between 1.0 mm and 10.0 mm; preferably in between 1.20 mm and 8.0 mm; more preferably in between 1.50 mm and 7.50 mm; even more preferably in between 2.0 mm and 6.0 mm. In some embodiments, the total thickness of the multilayer floor covering is measured according to EN ISO24346.

[0207] A further aspect provides a method to produce or manufacture a multilayer floor covering as disclosed herein.

[0208] In an embodiment, the method preferably comprises the steps of: a) providing a wear layer; b) applying a coating layer based on a polymer-in-water dispersion on the wear layer; c) applying a backing layer on the coating layer, wherein the backing layer is configured to overlie the coating layer such that the backing layer contacts the coating layer; wherein the backing layer, the coating layer, and the wear layer each comprise a thermoplastic polymer that is of the same family of thermoplastic polymers, wherein the backing layer, the coating layer, the wear layer are essentially free of PVC homopolymers and PVC polymers, and wherein the backing layer has an air permeability of at least 500 l / m2 / s measured at 200 Pascal according to ISO 9237, thereby forming a multilayer floor covering according to any of the embodiments as disclosed herein.

[0209] In some further embodiments, the backing layer, the coating layer and the wear layer are essentially free of plasticizers.

[0210] In some further embodiments, the method comprises a step b1) wherein after step b) a reinforcement layer is applied on the coating layer and wherein an additional coating layer based on a polymer-in-water dispersion is applied on the reinforcement layer, and wherein in step c) the backing layer is applied on the additional coating layer, wherein the backing layer is configured to overlie the additional coating layer such that the backing layer contacts the additional coating layer.

[0211] In another embodiment, the method preferably comprises the steps of: a) providing a backing layer with an air permeability of at least 500 l / m2 / s measured at 200 Pascal according to ISO 9237; b) applying a coating layer based on a polymer-in-water dispersion on the backing layer; c) applying a wear layer on the coating layer, wherein the wear layer is configured to overlie the coating layer such that the wear layer contacts the coating layer; wherein the backing layer, the coating layer, and the wear layer each comprise a thermoplastic polymer that is of the same family of thermoplastic polymers, and wherein the backing layer, the coating layer, and the wear layer are essentially free of PVC homopolymers and PVC polymers, thereby forming a multilayer floor covering according to any of the embodiments as disclosed herein.

[0212] In some further embodiments, the backing layer, the coating layer and the wear layer are essentially free of plasticizers.

[0213] In some further embodiments, the method comprises a step a1) wherein after step a) an additional coating layer based on a polymer-in-water dispersion is applied on the backing layer and wherein a reinforcement layer is applied on the additional coating layer and wherein in step b) the coating layer is applied on the reinforcement layer.

[0214] Typical for the method as disclosed herein is the combination of the lamination of all layers together in one production line.

[0215] In some embodiments, the wear layer is provided on a roll and is directed towards a first knife using a roll coating station.

[0216] In some embodiments, the wear layer as provided in step a) or c) of the method disclosed herein is a preprinted wear layer wherein the wear layer comprises a print pattern deposited on the surface of the wear layer that is on the side of the coating layer.

[0217] In some embodiments, the method comprises an additional step prior to step a) or step c) wherein a print pattern is deposited to the surface of the wear layer on the side of the coating layer.

[0218] Printing can comprise printing inks applied by rotogravure, flexographic or digital printing. These are convenient printing techniques.

[0219] In some embodiments, the coating layer is applied at a coating station in step b).

[0220] In some embodiments, step b) comprises the application of only one coating layer based on a polymer-in-water dispersion on the wear layer.

[0221] In some embodiments, step b) comprises the application of a first coating layer based on a polymer-in-water dispersion on the wear layer, followed by the application of a second coating layer based on a polymer-in-water dispersion on the first coating layer. In said embodiments, the coating layer thus comprises a first and a second coating layer. By applying a first and a second coating layer, the first coating layer can be formulated for optimal adhesion to the wear layer, whereas the second coating layer can be formulated for optimal adhesion to the first coating layer but also to obtain a higher filler loading. Also, both the first and the second coating layer can contribute to the overall stiffness, thickness and dimensional stability of the flooring product.

[0222] In some embodiments, the first coating layer is not foamed whereas the second coating layer is a foamed coating layer. In some embodiments, the second coating layer is not foamed whereas the first coating layer is a foamed coating layer. In some embodiments, both the first and second coating layer are foamed. Furthermore, the use of a separate second coating layer may also contribute to an increased overall performance of the floor covering by improving the residual indentation, the delamination strength, and the tear strength.

[0223] In some embodiments, the backing layer is applied on the coating layer in step c) such that the backing layer is laminated to the coating layer.

[0224] In some embodiments, the backing layer is provided in step a) and the wear layer is applied on the coating layer in step c) such that the wear layer is laminated to the coating layer.

[0225] In some embodiments, the backing layer can be provided wounded on a roll; preferably on a roll that has a core comprising cardboard. In some embodiments, the backing layer and the roll can be mounted in an unwinding machine and further threaded to a roller. In some further embodiments, pressure is put on the backing layer to remove any air present in between the backing layer and the coating layer, thereby ensuring a good bond between the backing layer and the coating layer.

[0226] In some embodiments, the method further comprises a step d) that comprises heating the floor covering to a temperature of at least 70.0°C to at most a temperature that is 20.0°C above the melting temperature of the thermoplastic polymer in the multilayer floor covering, thereby allowing the coating layer to fuse with the wear layer and the backing layer. In some further embodiments, step d) comprises heating the floor covering to a temperature of at least 70.0°C to at most a temperature that is 10.0 °C above the melting temperature of the thermoplastic polymer in the multilayer floor covering. In some further preferred embodiments, step d) comprises heating the floor covering to a temperature of at least 70.0°C to at most 270°C; preferably at least 80.0°C to at most 250°C; more preferably at least 80.0°C to at most 200°C; even more preferably at least 80°C to at most 180°C, or at least 80°C to at most 165°C, or at least 85°C to at most 160°C, or at least 85°C to at most 155°C. In some embodiments, step d) is performed in a thermal air dryer. In said drying step, the backing layer is on top such that any water present in the coating layer can evaporate more efficiently. In some embodiments, the method as disclosed herein further comprises a step e) that comprises embossing of the multilayer covering that is formed. In a particular embodiment, the method comprises embossing of the wear layer.

[0227] In some embodiments, the embossing is thermal embossing; preferably wherein the embossing is performed by infrared heating of the floor covering followed by cold pressing of a structure into the wear layer. As a result, the structure will be frozen into the wear layer.

[0228] In some embodiments, the embossing is cold embossing.

[0229] In some embodiment, the embossing is mechanical embossing.

[0230] In some embodiments, the wear layer that is provided in step a) is a pre-embossed wear layer and hence no embossing step e) needs to be applied.

[0231] In some embodiments, the method as disclosed herein further comprises a step f) that comprises applying a lacquer layer on the wear layer. Preferably said lacquer layer comprises polyurethane, polyacrylate, or a mixture thereof.

[0232] In a particular embodiment, a method to produce a multilayer floor covering is thus provided, said method comprising the steps of: a) providing a wear layer; b) applying a coating layer based on a polymer-in-water dispersion on the wear layer; c) applying a backing layer on the coating layer, wherein the backing layer is configured to overlie the coating layer such that the backing layer contacts the coating layer, d) heating the floor covering to a temperature of at least 70.0°C to at most a temperature that is 20.0°C above the melting temperature of the thermoplastic polymer in the multilayer floor covering; wherein the backing layer, the coating layer, and the wear layer each comprise a thermoplastic polymer that is of the same family of thermoplastic polymers; wherein the backing layer has an air permeability of at least 500 l / m2 / s measured at 200 Pascal according to ISO 9237, and wherein the backing layer, the coating layer, and the wear layer are essentially free of PVC homopolymers and PVC copolymers.

[0233] More preferably, the backing layer, the coating layer, and the wear layer are free of PVC homopolymers and PVC copolymers. In some further embodiments, the backing layer, the coating layer and the wear layer are essentially free of plasticizers. In some further embodiments, step d) comprises heating the floor covering to a temperature of at least 70.0°C to at most a temperature that is 10.0 °C above the melting temperature of the thermoplastic polymer in the multilayer floor covering. In some further preferred embodiments, step d) comprises heating the floor covering to a temperature of at least 70.0°C to at most 270°C; preferably at least 80.0°C to at most 250°C; more preferably at least 80.0°C to at most 200°C; even more preferably at least 80°C to at most 180°C, or at least 80°C to at most 165°C, or at least 85°C to at most 160°C, or at least 85°C to at most 155°C.

[0234] In another embodiment, a method to produce a multilayer floor covering is thus provided, said method comprising the steps of: a) providing a wear layer, and deposition of a print pattern to the surface of the wear layer that is on the side of the coating layer; b) applying a coating layer based on a polymer-in-water dispersion on the wear layer; c) applying a backing layer on the coating layer, wherein the backing layer is configured to overlie the coating layer such that the backing layer contacts the coating layer, d) heating the floor covering to a temperature of at least 70.0°C to at most a temperature that is 20.0°C above the melting temperature of the thermoplastic polymer in the multilayer floor covering; wherein the backing layer, the coating layer, and the wear layer each comprise a thermoplastic polymer that is of the same family of thermoplastic polymers; wherein the backing layer has an air permeability of at least 500 l / m2 / s as measured at 200 Pascal according to ISO 9237, and wherein the backing layer, the coating layer, and the wear layer are essentially free of PVC homopolymers and PVC copolymers.

[0235] In some further embodiments, step d) comprises heating the floor covering to a temperature of at least 70.0°C to at most a temperature that is 10.0 °C above the melting temperature of the thermoplastic polymer in the multilayer floor covering. In some further preferred embodiments, step d) comprises heating the floor covering to a temperature of at least 70.0°C to at most 270°C; preferably at least 80.0°C to at most 250°C; more preferably at least 80.0°C to at most 200°C; even more preferably at least 80°C to at most 180°C, or at least 80°C to at most 165°C, or at least 85°C to at most 160°C, or at least 85°C to at most 155°C.

[0236] Preferably, the backing layer, the coating layer, and the wear layer are free of PVC homopolymers and PVC copolymers. More preferably, the backing layer, the coating layer, and the wear layer are essentially free from plasticizers.

[0237] In another embodiment, a method to produce a multilayer floor covering is thus provided, said method comprising the steps of: a) providing a wear layer; b) applying a coating layer based on a polymer-in-water dispersion on the wear layer; c) applying a backing layer on the coating layer, wherein the backing layer is configured to overlie the coating layer such that the backing layer contacts the coating layer, d) heating the floor covering to a temperature of at least 70.0°C to at most a temperature that is 20.0°C above the melting temperature of the thermoplastic polymer in the multilayer floor covering; e) embossing of the wear layer; preferably thermally embossing of the wear layer; more preferably wherein the embossing is performed by infrared heating of the floor covering followed by cold pressing of a structure into the wear layer; wherein the backing layer, the coating layer, and the wear layer each comprise a thermoplastic polymer that is of the same family of thermoplastic polymers, wherein the backing layer has an air permeability of at least 500 l / m2 / s measured at 200 Pascal according to ISO 923, and wherein the backing layer, the coating layer, and the wear layer are essentially free of PVC homopolymers and PVC copolymers. More preferably, the backing layer, the coating layer, and the wear layer are free of PVC homopolymers and PVC copolymers. In some embodiments, the wear layer as provided in step a) is a preprinted wear layer wherein the wear layer comprises a print pattern deposited on the surface of the wear layer that is on the side of the coating layer. In some embodiments, the method comprises an additional step prior to step a) wherein a print pattern is deposited to the surface of the wear layer on the side of the coating layer. In some embodiments, the coating layer comprises one or more colorants or pigments.

[0238] In some further embodiments, step d) comprises heating the floor covering to a temperature of at least 70.0°C to at most a temperature that is 10.0 °C above the melting temperature of the thermoplastic polymer in the multilayer floor covering. In some further preferred embodiments, step d) comprises heating the floor covering to a temperature of at least 70.0°C to at most 270°C; preferably at least 80.0°C to at most 250.0°C; more preferably at least 80.0°C to at most 200.0°C; even more preferably at least 80°C to at most 180.0°C, or at least 80°C to at most 165.0°C, or at least 85.0°C to at most 160.0°C, or at least 85.0°C to at most 155.0°C. In another embodiment, a method to produce a multilayer floor covering is thus provided, said method comprising the steps of: a) providing a wear layer; b) applying a coating layer based on a polymer-in-water dispersion on the wear layer; c) applying a backing layer on the coating layer, wherein the backing layer is configured to overlie the coating layer such that the backing layer contacts the coating layer, d) heating the floor covering to a temperature of at least 70.0°C to at most a temperature that is 20.0°C above the melting temperature of the thermoplastic polymer in the multilayer floor covering; e) embossing of the wear layer; preferably thermally embossing of the wear layer; more preferably wherein the embossing is performed by infrared heating of the floor covering followed by cold pressing of a structure into the wear layer; f) applying a lacquer layer on the wear layer; preferably wherein the lacquer layer comprises polyurethane, polyacrylate, or a mixture thereof; wherein the backing layer, the coating layer, and the wear layer each comprise an identical thermoplastic polymer; wherein the backing layer, the coating layer, and the wear layer are essentially free of PVC homopolymers and PVC copolymers, and wherein the backing layer has an air permeability of at least 500 l / m2 / s measured at 200 Pascal according to ISO 9237. More preferably, the backing layer, the coating layer, and the wear layer are free of PVC homopolymers and PVC copolymers. In some embodiments, the wear layer as provided in step a) is a preprinted wear layer wherein the wear layer comprises a print pattern deposited on the surface of the wear layer that is on the side of the coating layer. In some embodiments, the method comprises an additional step prior to step a) wherein a print pattern is deposited to the surface of the wear layer on the side of the coating layer.

[0239] In some further embodiments, step d) comprises heating the floor covering to a temperature of at least 70.0°C to at most a temperature that is 10.0 °C above the melting temperature of the thermoplastic polymer in the multilayer floor covering. In some further preferred embodiments, step d) comprises heating the floor covering to a temperature of at least 70.0°C to at most 270°C; preferably at least 80.0°C to at most 250.0°C; more preferably at least 80.0°C to at most 200.0°C; even more preferably at least 80°C to at most 180.0°C, or at least 80.0°C to at most 165.0°C, or at least 85.0°C to at most 160.0°C, or at least 85.0°C to at most 155.0°C. In another embodiment, a method to produce a multilayer floor covering is thus provided, said method comprising the steps of: a) providing a wear layer; b) applying a coating layer based on a polymer-in-water dispersion on the wear layer; c) applying a backing layer on the coating layer, wherein the backing layer is configured to overlie the coating layer such that the backing layer contacts the coating layer, d) heating the floor covering to a temperature of at least 70.0°C to at most a temperature that is 20.0°C above the melting temperature of the thermoplastic polymer in the multilayer floor covering; e) applying a lacquer layer on the wear layer; preferably wherein the lacquer layer comprises polyurethane, polyacrylate, or a mixture thereof; wherein the backing layer, the coating layer, and the wear layer each comprise an identical thermoplastic polymer; wherein the backing layer has an air permeability of at least 500 l / m2 / s measured at 200 Pascal according to ISO 9237, and wherein the backing layer, the coating layer, and the wear layer are essentially free of PVC homopolymers and PVC copolymers. More preferably, the backing layer, the coating layer, and the wear layer are free of PVC homopolymers and PVC copolymers. In some embodiments, the wear layer as provided in step a) is a preprinted wear layer wherein the wear layer comprises a print pattern deposited on the surface of the wear layer that is on the side of the coating layer. In some embodiments, the method comprises an additional step prior to step a) wherein a print pattern is deposited to the surface of the wear layer on the side of the coating layer.

[0240] In some further embodiments, step d) comprises heating the floor covering to a temperature of at least 70.0°C to at most a temperature that is 10.0 °C above the melting temperature of the thermoplastic polymer in the multilayer floor covering. In some further preferred embodiments, step d) comprises heating the floor covering to a temperature of at least 70.0°C to at most 270.0°C; preferably at least 80.0°C to at most 250.0°C; more preferably at least 80.0°C to at most 200.0°C; even more preferably at least 80°C to at most 180.0°C, or at least 80.0°C to at most 165.0°C, or at least 85.0°C to at most 160.0°C, or at least 85.0°C to at most 155.0°C.

[0241] In another embodiment, a method to produce a multilayer floor covering is thus provided, said method comprising the steps of: a) providing combined layer that comprises a lacquer layer, a print pattern, and a wear layer; b) applying a coating layer based on a polymer-in-water dispersion on the combined layer; c) applying a backing layer on the coating layer, wherein the backing layer is configured to overlie the coating layer such that the backing layer contacts the coating layer, d) heating the floor covering to a temperature of at least 70.0°C to at most a temperature that is 20.0°C above the melting temperature of the thermoplastic polymer in the multilayer floor covering; wherein the backing layer, the coating layer, and the wear layer each comprise an identical thermoplastic polymer; wherein the backing layer has an air permeability of at least 500 l / m2 / s measured at 200 Pascal according to ISO 9237, and wherein the backing layer, the coating layer, and the wear layer are essentially free of PVC homopolymers and PVC copolymers. More preferably, the backing layer, the coating layer, and the wear layer are free of PVC homopolymers and PVC copolymers.

[0242] In some further embodiments, step d) comprises heating the floor covering to a temperature of at least 70.0°C to at most a temperature that is 10.0 °C above the melting temperature of the thermoplastic polymer in the multilayer floor covering. In some further preferred embodiments, step d) comprises heating the floor covering to a temperature of at least 70.0°C to at most 270.0°C; preferably at least 80.0°C to at most 250.0°C; more preferably at least 80.0°C to at most 200.0°C; even more preferably at least 80.0°C to at most 180.0°C, or at least 80.0°C to at most 165.0°C, or at least 85.0°C to at most 160.0°C, or at least 85.0°C to at most 155.0°C.

[0243] In another embodiment, a method to produce a multilayer floor covering is thus provided, said method comprising the steps of: a) providing a wear layer; b) applying a coating layer based on a polymer-in-water dispersion on the wear layer; b1) applying a reinforcement layer on the coating layer, followed by applying an additional coating layer based on a polymer-in-water dispersion on the reinforcement layer; c) applying a backing layer on the additional coating layer, wherein the backing layer is configured to overlie the additional coating layer such that the backing layer contacts the additional coating layer, d) heating the floor covering to a temperature of at least 70.0°C to at most a temperature that is 20.0°C above the melting temperature of the thermoplastic polymer in the multilayer floor covering; e) applying a lacquer layer on the wear layer; preferably wherein the lacquer layer comprises polyurethane, polyacrylate, or a mixture thereof; wherein the backing layer, the coating layer, the additional coating layer and the wear layer each comprise an identical thermoplastic polymer; wherein the backing layer has an air permeability of at least 500 l / m2 / s measured at 200 Pascal according to ISO 9237, and wherein the backing layer, the coating layer, the additional coating and the wear layer are essentially free of PVC homopolymers and PVC copolymers. More preferably, the backing layer, the coating layer, the additional coating layer and the wear layer are free of PVC homopolymers and PVC copolymers. In some embodiments, the wear layer as provided in step a) is a preprinted wear layer wherein the wear layer comprises a print pattern deposited on the surface of the wear layer that is on the side of the coating layer. In some embodiments, the method comprises an additional step prior to step a) wherein a print pattern is deposited to the surface of the wear layer on the side of the coating layer.

[0244] In some further embodiments, step d) comprises heating the floor covering to a temperature of at least 70.0°C to at most a temperature that is 10.0 °C above the melting temperature of the thermoplastic polymer in the multilayer floor covering. In some further preferred embodiments, step d) comprises heating the floor covering to a temperature of at least 70.0°C to at most 270.0°C; preferably at least 80.0°C to at most 250.0°C; more preferably at least 80.0°C to at most 200.0°C; even more preferably at least 80.0°C to at most 180.0°C, or at least 80.0°C to at most 165.0°C, or at least 85.0°C to at most 160.0°C, or at least 85.0°C to at most 155.0°C.

[0245] In another embodiment, a method to produce a multilayer floor covering is thus provided, said method comprising the steps of: a) providing a wear layer; b) applying a coating layer based on a polymer-in-water dispersion on the wear layer; b1) applying a reinforcement layer on the coating layer, followed by applying an additional coating layer based on a polymer-in-water dispersion on the reinforcement layer; c) applying a backing layer on the additional coating layer, wherein the backing layer is configured to overlie the additional coating layer such that the backing layer contacts the additional coating layer, d) heating the floor covering to a temperature of at least 70.0°C to at most a temperature that is 20.0°C above the melting temperature of the thermoplastic polymer in the multilayer floor covering; e) embossing of the wear layer; preferably thermally embossing of the wear layer; more preferably wherein the embossing is performed by infrared heating of the floor covering followed by cold pressing of a structure into the wear layer; f) applying a lacquer layer on the wear layer; preferably wherein the lacquer layer comprises polyurethane, polyacrylate, or a mixture thereof; wherein the backing layer, the coating layer, the additional coating layer and the wear layer each comprise an identical thermoplastic polymer; wherein the backing layer has an air permeability of at least 500 l / m2 / s measured at 200 Pascal according to ISO 9237, and wherein the backing layer, the coating layer, the additional coating layer and the wear layer are essentially free of PVC homopolymers and PVC copolymers. More preferably, the backing layer, the coating layer, the additional coating layer and the wear layer are free of PVC homopolymers and PVC copolymers. In some embodiments, the wear layer as provided in step a) is a preprinted wear layer wherein the wear layer comprises a print pattern deposited on the surface of the wear layer that is on the side of the coating layer. In some embodiments, the method comprises an additional step prior to step a) wherein a print pattern is deposited to the surface of the wear layer on the side of the coating layer.

[0246] In some further embodiments, step d) comprises heating the floor covering to a temperature of at least 70.0°C to at most a temperature that is 10.0 °C above the melting temperature of the thermoplastic polymer in the multilayer floor covering. In some further preferred embodiments, step d) comprises heating the floor covering to a temperature of at least 70.0°C to at most 270.0°C; preferably at least 80.0°C to at most 250.0°C; more preferably at least 80.0°C to at most 200.0°C; even more preferably at least 80.0°C to at most 180.0°C, or at least 80.0°C to at most 165.0°C, or at least 85.0°C to at most 160.0°C, or at least 85.0°C to at most 155.0°C.

[0247] In a particular embodiment, a method to produce a multilayer floor covering is thus provided, said method comprising the steps of: a) providing a backing layer; b) applying a coating layer based on a polymer-in-water dispersion on the backing layer; c) applying a wear layer on the coating layer, wherein the wear layer is configured to overlie the coating layer such that the wear layer contacts the coating layer, d) heating the floor covering to a temperature of at least 70.0°C to at most a temperature that is 20.0°C above the melting temperature of the thermoplastic polymer in the multilayer floor covering; wherein the backing layer, the coating layer, and the wear layer each comprise a thermoplastic polymer that is of the same family of thermoplastic polymers; wherein the backing layer has an air permeability of at least 500 l / m2 / s measured at 200 Pascal according to ISO 9237, and wherein the backing layer, the coating layer, and the wear layer are essentially free of PVC homopolymers and PVC copolymers.

[0248] More preferably, the backing layer, the coating layer, and the wear layer are free of PVC homopolymers and PVC copolymers.

[0249] In some further embodiments, step d) comprises heating the floor covering to a temperature of at least 70.0°C to at most a temperature that is 10.0 °C above the melting temperature of the thermoplastic polymer in the multilayer floor covering. In some further preferred embodiments, step d) comprises heating the floor covering to a temperature of at least 70.0°C to at most 270.0°C; preferably at least 80.0°C to at most 250.0°C; more preferably at least 80.0°C to at most 200.0°C; even more preferably at least 80.0°C to at most 180.0°C, or at least 80.0°C to at most 165.0°C, or at least 85.0°C to at most 160.0°C, or at least 85.0°C to at most 155.0°C.

[0250] In another embodiment, a method to produce a multilayer floor covering is thus provided, said method comprising the steps of: a) providing a backing layer; b) applying a coating layer based on a polymer-in-water dispersion on the backing layer; c) applying a pre-printed wear layer on the coating layer, wherein the wear layer is configured to overlie the coating layer such that the wear layer contacts the coating layer; d) heating the floor covering to a temperature of at least 70.0°C to at most a temperature that is 20.0°C above the melting temperature of the thermoplastic polymer in the multilayer floor covering; wherein the backing layer, the coating layer, and the wear layer each comprise a thermoplastic polymer that is of the same family of thermoplastic polymers; wherein the backing layer has an air permeability of at least 500 l / m2 / s measured at 200 Pascal according to ISO 9237, and wherein the backing layer, the coating layer, and the wear layer are essentially free of PVC homopolymers and PVC copolymers.

[0251] More preferably, the backing layer, the coating layer, and the wear layer are free of PVC homopolymers and PVC copolymers.

[0252] In some further embodiments, step d) comprises heating the floor covering to a temperature of at least 70.0°C to at most a temperature that is 10.0 °C above the melting temperature of the thermoplastic polymer in the multilayer floor covering. In some further preferred embodiments, step d) comprises heating the floor covering to a temperature of at least 70.0°C to at most 270.0°C; preferably at least 80.0°C to at most 250.0°C; more preferably at least 80.0°C to at most 200.0°C; even more preferably at least 80.0°C to at most 180.0°C, or at least 80.0°C to at most 165.0°C, or at least 85.0°C to at most 160.0°C, or at least 85.0°C to at most 155.0°C.

[0253] In another embodiment, a method to produce a multilayer floor covering is thus provided, said method comprising the steps of: a) providing a backing layer; b) applying a coating layer based on a polymer-in-water dispersion on the backing layer; c) applying a wear layer on the coating layer, wherein the wear layer is configured to overlie the coating layer such that the backing layer contacts the coating layer, d) heating the floor covering to a temperature of at least 70.0°C to at most a temperature that is 20.0°C above the melting temperature of the thermoplastic polymer in the multilayer floor covering; e) embossing of the wear layer; preferably thermally embossing of the wear layer; more preferably wherein the embossing is performed by infrared heating of the floor covering followed by cold pressing of a structure into the wear layer; wherein the backing layer, the coating layer, and the wear layer each comprise an identical thermoplastic polymer; wherein the backing layer has an air permeability of at least 500 l / m2 / s measured at 200 Pascal according to ISO 9237, and wherein the backing layer, the coating layer, and the wear layer are essentially free of PVC homopolymers and PVC copolymers. More preferably, the backing layer, the coating layer, and the wear layer are free of PVC homopolymers and PVC copolymers. In some embodiments, the wear layer as provided in step c) is a preprinted wear layer wherein the wear layer comprises a print pattern deposited on the surface of the wear layer that is on the side of the coating layer. In some embodiments, the method comprises an additional step prior to step c) wherein a print pattern is deposited to the surface of the wear layer on the side of the coating layer.

[0254] In some further embodiments, step d) comprises heating the floor covering to a temperature of at least 70.0°C to at most a temperature that is 10.0 °C above the melting temperature of the thermoplastic polymer in the multilayer floor covering. In some further preferred embodiments, step d) comprises heating the floor covering to a temperature of at least 70.0°C to at most 270.0°C; preferably at least 80.0°C to at most 250.0°C; more preferably at least 80.0°C to at most 200.0°C; even more preferably at least 80.0°C to at most 180.0°C, or at least 80.0°C to at most 165.0°C, or at least 85.0°C to at most 160.0°C, or at least 85.0°C to at most 155.0°C. In another embodiment, a method to produce a multilayer floor covering is thus provided, said method comprising the steps of: a) providing a backing layer; b) applying a coating layer based on a polymer-in-water dispersion on the backing layer; c) applying a wear layer on the coating layer, wherein the wear layer is configured to overlie the coating layer such that the wear layer contacts the coating layer, d) heating the floor covering to a temperature of at least 70.0°C to at most a temperature that is 20.0°C above the melting temperature of the thermoplastic polymer in the multilayer floor covering; e) embossing of the wear layer; preferably thermally embossing of the wear layer; more preferably wherein the embossing is performed by infrared heating of the floor covering followed by cold pressing of a structure into the wear layer; f) applying a lacquer layer on the wear layer; preferably wherein the lacquer layer comprises polyurethane, polyacrylate, or a mixture thereof; wherein the backing layer, the coating layer, and the wear layer each comprise an identical thermoplastic polymer; wherein the backing layer has an air permeability of at least 500 l / m2 / s measured at 200 Pascal according to ISO 9237, and wherein the backing layer, the coating layer, and the wear layer are essentially free of PVC homopolymers and PVC copolymers. More preferably, the backing layer, the coating layer, and the wear layer are free of PVC homopolymers and PVC copolymers. In some embodiments, the wear layer as provided in step a) is a preprinted wear layer wherein the wear layer comprises a print pattern deposited on the surface of the wear layer that is on the side of the coating layer. In some embodiments, the method comprises an additional step prior to step c) wherein a print pattern is deposited to the surface of the wear layer on the side of the coating layer.

[0255] In some further embodiments, step d) comprises heating the floor covering to a temperature of at least 70.0°C to at most a temperature that is 10.0 °C above the melting temperature of the thermoplastic polymer in the multilayer floor covering. In some further preferred embodiments, step d) comprises heating the floor covering to a temperature of at least 70.0°C to at most 270.0°C; preferably at least 80.0°C to at most 250.0°C; more preferably at least 80.0°C to at most 200.0°C; even more preferably at least 80.0°C to at most 180.0°C, or at least 80.0°C to at most 165.0°C, or at least 85.0°C to at most 160.0°C, or at least 85.0°C to at most 155.0°C.

[0256] In another embodiment, a method to produce a multilayer floor covering is thus provided, said method comprising the steps of: a) providing a backing layer; b) applying a coating layer based on a polymer-in-water dispersion on the backing layer; c) applying a wear layer on the coating layer, wherein the wear layer is configured to overlie the coating layer such that the wear layer contacts the coating layer, d) heating the floor covering to a temperature of at least 70.0°C to at most a temperature that is 20.0°C above the melting temperature of the thermoplastic polymer in the multilayer floor covering; e) applying a lacquer layer on the wear layer; preferably wherein the lacquer layer comprises polyurethane, polyacrylate, or a mixture thereof; wherein the backing layer, the coating layer, and the wear layer each comprise an identical thermoplastic polymer; wherein the backing layer has an air permeability of at least 500 l / m2 / s measured at 200 Pascal according to ISO 9237, and wherein the backing layer, the coating layer, and the wear layer are essentially free of PVC homopolymers and PVC copolymers. More preferably, the backing layer, the coating layer, and the wear layer are free of PVC homopolymers and PVC copolymers. In some embodiments, the wear layer as provided in step a) is a preprinted wear layer wherein the wear layer comprises a print pattern deposited on the surface of the wear layer that is on the side of the coating layer. In some embodiments, the method comprises an additional step prior to step c) wherein a print pattern is deposited to the surface of the wear layer on the side of the coating layer.

[0257] In some further embodiments, step d) comprises heating the floor covering to a temperature of at least 70.0°C to at most a temperature that is 10.0 °C above the melting temperature of the thermoplastic polymer in the multilayer floor covering. In some further preferred embodiments, step d) comprises heating the floor covering to a temperature of at least 70.0°C to at most 270.0°C; preferably at least 80.0°C to at most 250.0°C; more preferably at least 80.0°C to at most 200.0°C; even more preferably at least 80.0°C to at most 180.0°C, or at least 80.0°C to at most 165.0°C, or at least 85.0°C to at most 160.0°C, or at least 85.0°C to at most 155.0°C.

[0258] In another embodiment, a method to produce a multilayer floor covering is thus provided, said method comprising the steps of: a) providing a backing layer; a1) applying an additional coating layer based on a polymer-in-water dispersion on the backing layer followed by applying a reinforcement layer on the additional coating layer; b) applying a coating layer based on a polymer-in-water dispersion on the reinforcement layer; c) applying a wear layer on the coating layer, wherein the wear layer is configured to overlie the coating layer such that the wear layer contacts the coating layer, d) heating the floor covering to a temperature of at least 70.0°C to at most a temperature that is 20.0°C above the melting temperature of the thermoplastic polymer in the multilayer floor covering; e) embossing of the wear layer; preferably thermally embossing of the wear layer; more preferably wherein the embossing is performed by infrared heating of the floor covering followed by cold pressing of a structure into the wear layer; f) applying a lacquer layer on the wear layer; preferably wherein the lacquer layer comprises polyurethane, polyacrylate, or a mixture thereof; wherein the backing layer, the coating layer, and the wear layer each comprise an identical thermoplastic polymer; wherein the backing layer has an air permeability of at least 500 l / m2 / s measured at 200 Pascal according to ISO 9237, and wherein the backing layer, the coating layer, and the wear layer are essentially free of PVC homopolymers and PVC copolymers. More preferably, the backing layer, the coating layer, and the wear layer are free of PVC homopolymers and PVC copolymers. In some embodiments, the wear layer as provided in step a) is a preprinted wear layer wherein the wear layer comprises a print pattern deposited on the surface of the wear layer that is on the side of the coating layer. In some embodiments, the method comprises an additional step prior to step c) wherein a print pattern is deposited to the surface of the wear layer on the side of the coating layer.

[0259] In some further embodiments, step d) comprises heating the floor covering to a temperature of at least 70.0°C to at most a temperature that is 10.0 °C above the melting temperature of the thermoplastic polymer in the multilayer floor covering. In some further preferred embodiments, step d) comprises heating the floor covering to a temperature of at least 70.0°C to at most 270.0°C; preferably at least 80.0°C to at most 250.0°C; more preferably at least 80.0°C to at most 200.0°C; even more preferably at least 80.0°C to at most 180.0°C, or at least 80.0°C to at most 165.0°C, or at least 85.0°C to at most 160.0°C, or at least 85.0°C to at most 155.0°C.

[0260] In another embodiment, a method to produce a multilayer floor covering is thus provided, said method comprising the steps of: a) providing a backing layer; a1) applying an additional coating layer based on a polymer-in-water dispersion on the backing layer, followed by applying a reinforcement layer on the additional coating layer; b) applying a coating layer based on a polymer-in-water dispersion on the reinforcement layer; c) applying a wear layer on the coating layer o, wherein the wear layer is configured to overlie the coating layer such that the wear layer contacts the coating layer, d) heating the floor covering to a temperature of at least 70.0°C to at most a temperature that is 20.0°C above the melting temperature of the thermoplastic polymer in the multilayer floor covering; e) applying a lacquer layer on the wear layer; preferably wherein the lacquer layer comprises polyurethane, polyacrylate, or a mixture thereof; wherein the backing layer, the coating layer, and the wear layer each comprise an identical thermoplastic polymer; wherein the backing layer has an air permeability of at least 500 l / m2 / s measured at 200 Pascal according to ISO 9237, and wherein the backing layer, the coating layer, and the wear layer are essentially free of PVC homopolymers and PVC copolymers. More preferably, the backing layer, the coating layer, and the wear layer are free of PVC homopolymers and PVC copolymers. In some embodiments, the wear layer as provided in step a) is a preprinted wear layer wherein the wear layer comprises a print pattern deposited on the surface of the wear layer that is on the side of the coating layer. In some embodiments, the method comprises an additional step prior to step c) wherein a print pattern is deposited to the surface of the wear layer on the side of the coating layer.

[0261] In some further embodiments, step d) comprises heating the floor covering to a temperature of at least 70.0°C to at most a temperature that is 10.0 °C above the melting temperature of the thermoplastic polymer in the multilayer floor covering. In some further preferred embodiments, step d) comprises heating the floor covering to a temperature of at least 70.0°C to at most 270.0°C; preferably at least 80.0°C to at most 250.0°C; more preferably at least 80.0°C to at most 200.0°C; even more preferably at least 80.0°C to at most 180.0°C, or at least 80.0°C to at most 165.0°C, or at least 85.0°C to at most 160.0°C, or at least 85.0°C to at most 155.0°C.

[0262] It will be appreciated that in the present invention in some embodiments, the layers are assembled upside down, contrary to traditional assembly. The coating layer can be applied to the wear layer, which has been placed upside-down. The backing layer can be placed on top of the coating layer. This results in some embodiments in a final product that has been assembled upside-down, contrary to traditional methods whereby the coating layer is applied onto the backing layer instead.

[0263] The present invention also relates to a production line for performing the method as disclosed herein, and (preferred) embodiments thereof. A production line preferably comprises a series of machines installed one after another in the desired order, and preferably comprises one or more, preferably all, of the following units: a device for unwinding and controlling the tension of the wear layer; a coating station to apply the coating layer; a device for unwinding of a backing layer; an oven for final heat treatment; and / or, a winding station for finished floor covering.

[0264] Optionally, embossing stations and back print units may be installed and used during production. An exemplary production line is provided in Figure 6.

[0265] Also optionally, a lacquering station may be installed and used during production. The lacquering station can be water- based, UV-based or solvent-based. It will be understood that, depending on the type of lacquer applied, the lacquering station may have different curing equipment, such as UV lacquering will be done with UV light, whereas water-based lacquering will be done with a heated oven.

[0266] Preferably, at the beginning, a roll of wear layer with a print pattern may be installed in an unwinding machine and attached to a temporary material to tighten in a line in the direction of web travel, such that the wear layer will reach the coating station upside-down.

[0267] Once the wear layer reaches the coating station, the coating layer is applied on the wear layer. As the wear layer moves forward, the polymer-in-water dispersion is equally distributed for the whole width of the wear layer thereby forming the coating layer. The coating station as used herein can be any suitable coating station, such as a knife-over-roll station, a knife-over-table station, a direct spread coating station, a kiss-roll coating station or a spraying station. For example, a doctor blade, a rolling knife or any other application system may distribute the polymer-in-water dispersion equally for the whole width of the wear layer thereby forming the coating layer. A doctor blade will also allow the water to evaporate after the coating step and to allow fusion of the thermoplastic polymer in the different layers, in particular in the coating layer, the backing layer and wear layer.

[0268] Subsequently, an unwinding station may start to drop the backing layer onto the wear layer with the coating layer already applied.

[0269] When all layers of floor covering are applied, a heating step is applied on the floor covering, preferably at a temperature of at least 70.0°C and at most a temperature that is 20.0°C above the melting temperature of the thermoplastic polymer in the multilayer floor covering, thereby allowing the different layers to fuse with each other. In some further embodiments, heating can be performed at a temperature of at least 70.0°C to at most a temperature that is 10.0 °C above the melting temperature of the thermoplastic polymer in the multilayer floor covering. In some further preferred embodiments, heating can be performed at a temperature of at least 70.0°C to at most 270.0°C; preferably at least 80.0°C to at most 250.0°C; more preferably at least 80.0°C to at most 200.0°C; even more preferably at least 80.0°C to at most 180.0°C, or at least 80.0°C to at most 165.0°C, or at least 85.0°C to at most 160.0°C, or at least 85.0°C to at most 155.0°C.

[0270] Afterwards, the floor covering may be cooled down.

[0271] At the end of the production line, optionally embossing can be applied on the floor covering.

[0272] The present invention has the advantage that no changes are needed: standard technology may be used to produce floor covering that is essentially free of PVC. The present invention uses the wear layer to apply the coating layer upon, contrary to common practice. This upsidedown assembly allows for simple construction and proper adhesion, even without PVC. The present invention has found that this method allows to obtain a 100% PVC-free structure, using existing machinery, while avoiding the use of glass fibre and hard temperature regimes. The present method also allows to achieve an improved scratch resistance.

[0273] In another aspect, an apparatus or production line for manufacturing a multilayer floor covering as disclosed herein is provided, 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.

[0274] The apparatus or production line preferably comprises a roll configured for providing a wear layer. The apparatus or production line further preferably comprises a coating station, such as a coating station using a coating knife, to apply the coating layer to the wear layer. The apparatus or production line may further comprise a roll to apply the backing layer on the coating layer, more preferably also a nip roll is provided to guide the backing layer. The apparatus or production line preferably comprises a guiding system to a lamination point. The apparatus or production line preferably comprises a lamination station, preferably configured to laminate the layers at the lamination point. The lamination station may also control the tension and pressure on the backing layer thereby ensuring a good adhesion without creases or bubbles between the different layers. The apparatus or production line preferably comprises an oven, preferably an air-heated oven, to allow heating of the floor covering thereby laminating and fusing the different layers to each other. In some embodiments, the production line or apparatus may further comprise a cooling station to allow cooling down of the floor covering. In some preferred embodiments, the apparatus or production line further comprises an embossing station to emboss the floor covering. In some embodiments, said embossing station is an infrared heating embossing station. EXAMPLES

[0275] 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.

[0276] FIG. 1 illustrates a multilayer floor covering (1) according to an embodiment of the invention. The floor covering (1) comprises a backing layer (2), a coating layer (3), and a wear layer (4).

[0277] FIG. 2 Illustrates a multilayer floor covering (1) according to an embodiment of the invention. The floor covering (1) comprises a backing layer (2), a coating layer (3), a print pattern (5), and a wear layer (4).

[0278] FIG. 3 illustrates a multilayer floor covering (1) according to an embodiment of the invention. The floor covering (1) comprises a backing layer (2), a coating layer (3), a print pattern (5), a wear layer (4), and a lacquer layer (6).

[0279] FIG. 4 illustrates a multilayer floor covering (1) according to an embodiment of the invention. The floor covering (1) comprises a backing layer (2), an additional coating layer (7), a reinforcement layer (8), a coating layer (3), a print pattern (5) and a wear layer (4).

[0280] FIG. 5 illustrates a multilayer floor covering (1) according to an embodiment of the invention. The floor covering (1) comprises a backing layer (2), an additional coating layer (7), a reinforcement layer (8), a coating layer (3) and a wear layer (4). In some embodiments, the wear layer can already comprise a print pattern.

[0281] FIG. 6 illustrates a schematic representation of a method for the manufacture of a multilayer floor covering according to an embodiment of the invention. A first coating layer (3a) and, optionally, a second coating layer (3b), are applied on a wear layer (4) with a print pattern (5), followed by the application of a backing layer (2) on the coating layer, thereby forming a multilayer floor covering according to an embodiment of the invention.

[0282] FIG. 7 illustrates a method for the manufacture of a multilayer floor covering according to an embodiment of the invention. In a first step, a wear layer (4) is provided wounded on a roll (11). The wear layer (4) comprises a print pattern (5) deposited on the surface of the wear layer that is on the side of the coating layer. In a further step, the wear layer (4) is coated with a coating layer (3) based on a polymer-in-water dispersion. The coating is applied at the coating station using a coating knife (12). In a further step, a backing layer (2) is applied on the coating layer, wherein the backing layer is configured to overlie the coating layer (3) such that the backing layer (2) contacts the coating layer (3). As shown in the figure, the backing layer (2) can be provided on a roll (13) and guided to a nip roll (14). After application of the backing layer (2) on the coating layer (3), the floor covering is laminated and heated in an airheated oven (15) to allow the layers to fuse with each other.

[0283] Several multilayer floor products according to an embodiment of the invention were manufactured and tested. A summary of the different samples and their composition is provided in Table 1.

[0284] In samples 1-4, 7-13 and A-E, the ethylene-propylene copolymer in the coating layer has a viscosity of 4000 cP. In samples 5 and 6, the ethylene-propylene copolymer in the coating layer has a viscosity of 10000 cP.

[0285] In all samples, the coating layer was applied based on a polymer-in-water dispersion comprising 35.0 wt% of the polymer fraction (ethylene-propylene copolymer), 35.0 wt% of filler material and 30.0 wt% of water.

[0286] In sample 11 a commercial wear layer comprising polypropylene was used.

[0287] In samples 12, 13, C, D and E a commercial wear layer comprising polypropylene was used. In said commercial layer, also a lacquer layer and a print layer are present.

[0288] Samples 3-4 and 6 are prepared by first providing the backing layer, followed by application of the coating layer and wear layer respectively. Samples 1-2, 5, 7-13 and A-E are prepared by first providing the wear layer followed by application of the coating layer and backing layer respectively. During manufacture of the samples, the different layers were heated to a temperature in between 120°C and 160°C to allow the different layers to fuse together.

[0289] The multilayer floor product samples of Table 1 were tested to define the following parameters: delamination strength (N), indentation (mm), thickness (mm), weight g / m2), coating weight (g / m2), tear strength (N), dimensional stability (%) and curling (mm), air permeability of the backing layer (l / m2 / s), bending stiffness (N.mm) (Table 2 and 3).

[0290] All tests were performed according to the corresponding ISO standards as disclosed herein: delamination strength (EN ISO 24345), indentation (EN ISO 24343-1), thickness (EN ISO 24346), weight (EN ISO 23997), tear strength (EN ISO 432), dimensional stability and curling (EN ISO 23999), air permeability (EN ISO 9237), bending stiffness (modified EN ISO 5628 as disclosed herein).

[0291] Additionally, Table 4 shows thickness measurements of samples from another batch made according to the same manufacturing method used to make the samples in Table 2 and 3. The coating thicknesses in Table 4 were obtained by measuring on photos of cross sections of the samples. The data in Tables 2-4 shows that the coating thickness lies between 0.27 and 2 mm. The coating layer can be partly absorbed by the backing layer, so it has to be sufficiently thick to also provide adhesion to the layer on the opposite side. Table 1. Overview of the different floor covering samples according to an embodiment of the invention. Table 2

[0292] Table 3

[0293] A rule of thumb gives that 1000 g / m2coating weight corresponds to approximately 1 mm coating thickness.

[0294] Table 4

Claims

58CLAIMS1. A multilayer floor covering (1) comprising, in following order:- a backing layer (2);- a coating layer (3); and- a wear layer (4); wherein the backing layer (2), the coating layer (3), and the wear layer (4) each comprise a thermoplastic polymer that is of the same family of thermoplastic polymers, wherein the backing layer (2), the coating layer (3), and the wear layer (4) are essentially free of polyvinyl chloride (PVC) homopolymers and PVC copolymers, wherein the coating layer is based on a polymer-in-water dispersion, and wherein the backing layer (2) has an air permeability of at least 500 l / m2 / s measured at 200 Pascal according to ISO 9237.

2. The multilayer floor covering (1) of claim 1 wherein the backing layer (2), the coating layer (3) and the wear layer (4) are essentially free of any polymer other than the thermoplastic polymer that is of the same family of thermoplastic polymers.

3. The multilayer floor covering of claim 1 or 2 wherein the thermoplastic polymer is a polymer of the family of polyolefins, polystyrenes, polyesters, or polyamides; preferably wherein the thermoplastic polymer is a polyolefin selected from the group consisting of polypropylene (PP), polyethylene (PE), ethylene-propylene copolymer, ethylene-butene copolymer, ethyleneoctene copolymer, butadiene-propylene copolymer; or wherein the thermoplastic polymer is ethylene vinyl acetate (EVA) or ethylene methyl acetate (EMA); or wherein the thermoplastic polymer is a polystyrene selected from polystyrene (PS), or styrene-propylene copolymer; or wherein the thermoplastic polymer is a polyester selected from polyethylene terephthalate (PET), co-PET, polyethylene terephthalate glycol (PETG), polybutylene terephthalate (PBT), polylactic acid (PLA), or polycaprolactone (PCL); or wherein the thermoplastic polymer is a polyamide or co-polyamide; more preferably wherein the thermoplastic polymer is PP, PE, ethylene-propylene copolymer, ethylene-butene copolymer, ethylene-octene copolymer, PET, or co-PET.

4. The multilayer floor covering of any one of claims 1 to 3, wherein the backing layer (2) has an air permeability of at least 750 l / m2.s measured at 200 Pascal according to ISO 9237; preferably at least 1000 l / m2.s measured at 200 Pascal according to ISO 9237.

595. The multilayer floor covering of any one of claims 1 to 4, wherein the multilayer floor covering has a bending stiffness of at most 800 N.mm; preferably as measured using modified bending stiffness test according to ISO 5628, wherein the bending stiffness is measured at an angle of 30°.

6. The multilayer floor covering of any one of claims 1 to 5, wherein the polymer-in-water dispersion comprises an inorganic filler; preferably at least 0.50 wt% of an inorganic filler; more preferably at least 0.50 wt% and at most 45.0 wt% of an inorganic filler; even more preferably at least 1.0 wt% and at most 40.0 wt% of an inorganic filler, based on the total weight of the polymer-in-water dispersion.

7. The multilayer floor covering of any one of claims 1 to 6, further comprising a reinforcement layer (8) and an additional coating layer (7) based on a polymer-in-water dispersion, wherein said reinforcement layer (8) and additional coating layer (7) are located in between the coating layer (3) and the backing layer (2), with the additional coating layer (7) being in contact with the backing layer (2) and the reinforcement layer (8) being in contact with the coating layer (3), and wherein the additional coating layer (7) comprises a thermoplastic polymer that is of the same family of thermoplastic polymers as the thermoplastic polymer in the backing layer (2), the coating layer (3) and the wear layer (4) and wherein the additional coating layer (7) is essentially free of polyvinyl chloride (PVC) homopolymers and PVC copolymers.

8. The multilayer floor covering of any one of claims 1 to 7, further comprising a lacquer layer (6) that is located on the wear layer; preferably wherein the lacquer layer (6) comprises polyurethane, polyacrylate, or a mixture thereof.

9. The multilayer floor covering of any one of claims 1 to 8, wherein the multilayer floor covering (1) is free of PVC homopolymers and PVC copolymers; more preferably wherein the multilayer floor covering (1) is free of PVC homopolymers, PVC copolymers and plasticizers.

10. A method to produce a multilayer floor covering (1) according to any one of claims 1 to 9, said method comprising the steps of: a) providing a wear layer (4); b) applying a coating layer (3) based on a polymer-in-water dispersion on the wear layer; c) applying a backing layer (2) on the coating layer (3), wherein the backing layer is configured to overlie the coating layer (3) such that the backing layer (2) contacts60 the coating layer (3), and wherein the backing layer (2) has an air permeability of at least 500 l / m2 / s measured at 200 Pascal according to ISO 9237.

11. The method according to claim 10 further comprising a step b1) wherein after step b) a reinforcement layer (8) is applied on the coating layer (3) and wherein an additional coating layer (7) based on a polymer-in-water dispersion is applied on the reinforcement layer (8), and wherein in step c) the backing layer is applied on the additional coating layer (7), wherein the backing layer is configured to overlie the additional coating layer (7) such that the backing layer (2) contacts the additional coating layer (7).

12. A method to produce a multilayer floor covering (1) according to any one of claims 1 to 9, said method comprising the steps of: a) providing a backing layer (2) that has an air permeability of at least 500 l / m2 / s measured at 200 Pascal according to ISO 9237; b) applying a coating layer (3) based on a polymer-in-water dispersion on the backing layer (2); c) applying a wear layer (4) on the coating layer (3), wherein the wear layer is configured to overlie the coating layer (3) such that the wear layer (4) contacts the coating layer (3).

13. The method according to claim 12 further comprising a step a1) wherein after step a) an additional coating layer (7) based on a polymer-in-water dispersion is applied on the backing layer (2) and wherein a reinforcement layer (8) is applied on the additional coating layer (7) and wherein in step b) the coating layer (3) is applied on the reinforcement layer (8).

14. The method according to any one of claims 10 to 13, further comprising:- a step d) that comprises heating the floor covering to a temperature of at least 70.0°C to at most a temperature that is 20.0°C above the melting temperature of the thermoplastic polymer in the multilayer floor covering; thereby allowing the water in the polymer-in-water dispersion to evaporate and to fuse the different layers with each other;- a step e) that comprises embossing of the wear layer (4); preferably thermally embossing of the wear layer (4) or cold embossing of the wear layer (4); more preferably wherein the embossing is performed by infrared heating of the floor covering followed by cold pressing of a structure into the wear layer (4); and / or- a step f) that comprises applying a lacquer layer (6) above the wear layer (4) on the opposite side of the coating layer (3), preferably wherein the lacquer layer (6) comprises polyurethane, polyacrylate, or a mixture thereof.

15. The method of any one of claims 10 to 14 to manufacture a multilayer floor covering (1) according to any one of the claims 1 to 9.

16. A multilayer floor covering (1) manufactured by the method of any one of claims 10 to 14.

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