Multilayer Structure for the Production of a Heating Floor or Wall Covering

Abstract

A multilayer structure for the production of a heating floor or wall covering or similar includes a decorative layer made up of at least one plastic surface layer. The decorative layer is bonded onto a heating layer, which heating layer is bonded onto a sublayer intended to be installed on the floor or a wall or the like. The heating layer is made up of a conductive band comprising conductive particles homogeneously distributed over the surface and/or in the thickness of said conductive band, which supports at least three conductive electrodes spaced from one another so as to define a discontinuous heating surface.

Claims

1. A multilayer structure for the production of a heating floor or wall covering or similar, said multilayer structure comprising a decorative layer made up of at least one plastic surface layer, said decorative layer being bonded onto a heating layer, said heating layer being bonded onto a sublayer intended to be installed on the floor or a wall or the like, wherein the heating layer comprises a conductive band comprising conductive particles homogeneously distributed over the surface and/or in the thickness of said conductive band, said conductive band supporting at least three conductive electrodes, and said conductive electrodes being spaced from one another and configured so as to define a discontinuous heating surface.

2. A multilayer structure according to claim 1, wherein the conductive band, supports at least two pairs of conductive electrodes, said electrodes being spaced apart and configured so as to define a discontinuous heating surface.

3. A multilayer structure according to claim 1, wherein the heating layer comprises at least two conductive bands disposed side-by-side and spaced from one another, said conductive bands comprising conductive particles distributed homogeneously over the surface and/or in the thickness of said conductive bands, and each conductive band supporting two conductive electrodes with said electrodes being spaced from one another so as to define a discontinuous heating surface.

4. A multilayer structure according to claim 3, wherein the electrodes are disposed along the longitudinal edges of the conductive bands.

5. A multilayer structure according to claim 1, wherein the multilayer structure is made in the form of a band and the one or more conductive bands extend along said band.

6. A multilayer structure according to claim 1, wherein the multilayer structure is made in the form of a band and the one or more conductive bands extend transversely to said band.

7. A multilayer structure according to claim 1, wherein the electrodes are conductive ribbons.

8. A multilayer structure according to claim 1, wherein the thickness of the electrodes is less than 100 μm.

9. A multilayer structure according to claim 1, wherein the heating layer comprises a dielectric layer bonded onto the decorative layer and a dielectric layer bonded onto the sublayer.

10. A multilayer structure according to claim 1, wherein each conductive band is made of plastic.

11. A multilayer structure according to claim 1, wherein each conductive band is made of a nonwoven textile.

12. A multilayer structure according to claim 11, wherein the nonwoven textile has a grammage of between 25 g/m.sup.2 and 80 g/m.sup.2.

13. A multilayer structure according to claim 1, wherein the conductive particles that comprise the one or more conductive bands are carbon fibers.

14. A multilayer structure according to claim 1, wherein the heating layer comprises a reinforcement arranged in contact with the conductive bands.

Description

BRIEF DESCRIPTION OF THE FIGURES

[0067] Further advantages and features will become clearer from the following description, given by way of a non-limiting example, of the multilayer structure for the implementation of a heating floor or wall coating from the accompanying drawings in which:

[0068] FIG. 1 shows the multilayer structure schematically and in transverse cross section;

[0069] FIG. 2 shows an embodiment schematically and in top view;

[0070] FIG. 3 shows an alternative multilayer structure schematically and in transverse cross section;

[0071] FIG. 4 shows an alternative implementation of the multilayer structure schematically and in top view.

[0072] FIG. 5 shows a multilayer structure schematically and in transverse cross section;

[0073] FIG. 6 shows an embodiment schematically and in top view;

[0074] FIG. 7 shows a multilayer structure installed in an crowded room;

[0075] FIG. 8 shows an alternative implementation of the multilayer structure.

DETAILED DESCRIPTION

[0076] With reference to FIG. 1, the presently described embodiments relate to a multilayer structure (1) for implementing a heating floor or wall or similar covering, i.e. allowing the heating of the room in which the structure is installed.

[0077] The multilayer structure (1) can be made in panel, slab, band or roll form. The multilayer structure (1) is intended for the implementation of floor or wall covering installed bonded, semi-floating or floating, with high performance in terms of sealing and traffic resistance.

[0078] The multilayer structure (1) comprises an upper decorative layer (2) made up of at least one plastic surface layer (2a), bonded onto a heating layer (4), said heating layer (4) being bonded onto a lower sublayer (3) intended to be installed on the floor or a wall or the like. The heating layer includes a conductive band (4a) comprising conductive particles homogeneously distributed over the surface and/or in the thickness of said conductive band (4a), said conductive band (4a) supporting at least three conductive electrodes (5a, 5b, 5c), and said conductive electrodes being spaced from one another and configured so as to define a discontinuous heating surface.

[0079] The upper decorative layer (2) and the lower sublayer (3) can have diverse and varied compositions and structures depending on the application considered.

[0080] For that purpose, the decorative layer (2) comprises a surface layer (2a) made of polyvinyl chloride comprising a thickness of between 0.2 and 1 mm. Said surface layer (2a) can be colored in the mass and comprise decorative granules throughout the thickness thereof. Preferably, and for satisfying, for example, a U4 P3 rating under the French standard UPEC, the surface layer (2a) comprises a density of between 1.4 and 1.6, a residual dent of less than 0.10 mm and 25,000 cycle chair caster resistance. The surface layer (2a) can be transparent and combined with a printed decorative layer (not shown) on the back surface thereof, specifically on the surface thereof opposite the heating layer (4). The decorative imprinted layer generally comprises a thickness of between 0.07 and 0.5 mm.

[0081] The decorative layer (2) is bonded for example by hot lamination or by means of an adhesive layer (not shown) to the heating layer (4). The heating layer (4) comprises a conductive band (4a), produced for example from a nonwoven textile impregnated with conductive particles, specifically fiberglass impregnated with carbon fibers, with a grammage of between 25 g/m.sup.2 and 80 g/m.sup.2, advantageously between 25 g/m.sup.2 and 40 g/m.sup.2. A conductive band produced from a nonwoven fiberglass textile impregnated with carbon fibers with a grammage of 30 g/m.sup.2 has a resistance of between 4 and 5 ohms over a distance of 40 cm.

[0082] The conductive band (4a) supports at least three conductive electrodes (5a, 5b, 5c) spaced from one another so as to define a discontinuous heating surface. The heating surface thus extends between each electrode supported by a conductive band. Obviously, the grammage of the nonwoven textile of the conductive band and the quantity of conductive particles could be adjusted to obtain the desired resistivity value depending on the size of the heating surface.

[0083] The conductive electrodes (5a, 5b, 5c) are ribbons disposed in the center and along the longitudinal edges of the conductive band (4a) such that the heating surface extends over almost all of the surface of the multilayer structure thus formed. The resulting heating surface extends between the electrodes (5a, 5b) and (5b, 5c). In the case of a structure (1) produced in the shape of a band, the heating surface extends in the longitudinal direction of the band thus produced and between the electrodes (5a, 5b) and (5b, 5c).

[0084] The electrodes (5a, 5b, 5c) are for example ribbons made of a 40 μm thick copper strap. The electrodes (5a, 5b, 5c) are for example bonded onto each conductive band by a 25 μm thick layer of conductive adhesive.

[0085] Advantageously the heating layer (4) comprises a dielectric layer (6) bonded onto the decorative layer (2).

[0086] Advantageously the heating layer (4) comprises a dielectric layer (7) bonded onto the sublayer (3).

[0087] As it relates to the lower sublayer (3), it comprises a balancing layer (3a) of plastic, such as polyvinyl chloride, preferably comprising a thickness of 2 mm. Preferably, and in order to satisfy for example the French UPEC standard classification U4 P3, the balancing sheet (3a) has a Shore hardness A of between 80 and 95. Said balancing layer (3a) can also be a PVC or polyurethane foam in order to confer acoustic and/or thermal insulation properties to the floor or wall covering. In the case where said balancing layer (3a) is foam, the density thereof is between 0.2 and 0.9.

[0088] Said balancing layer (3a) is next bonded, by hot lamination for example, onto the heating layer (4).

[0089] A textile reinforcement (not shown) can also be embedded in the sublayer (3) and/or the decorative layer (2). Said reinforcement has for example the form of a grid or screen of textile yarns of negligible thickness, or even a fiberglass mat. The textile yarns of said reinforcement are, preferably, spaced from one another by 3 mm along the longitudinal and transverse dimensions and have a linear mass density of between 20 g/m and 70 g/m, advantageously between 35 g/m and 50 g/m. A reinforcement enables the mechanical performance and resistance of the floor or wall coating to indentation and rolling to be increased. The reinforcement also provides dimensional stability of the covering over time.

[0090] The arrangement of the decorative layer (2) and the sublayer (3) are given as nonlimiting examples. It is obvious that depending on the application considered, layers can be added to or removed from the multilayer structure (1) described.

[0091] As an example, the multilayer structure (1) described below is intended to be used for example in hospitals or in a school environment. The multilayer structure (1) has good mechanical performance in terms of resistance to indentation and rolling and incorporates heating functions.

[0092] In the case where the conductive band (4a) is made of a nonwoven textile, the conductive band can be used as coating support in a fabrication method for the multilayer structure. For this purpose, the conductive band is laminated with a reinforcement (8), such as a fiberglass mat and/or fiberglass grid. In this way a reinforced coating support can be obtained. The width of the reinforcement (8) is advantageously greater than the width of the conductive band (4a). The electrodes (5a, 5b, 5c) are spaced from one another and then bonded onto the conductive band (4a). Alternatively, the electrodes (5a, 5b, 5c) are spaced from one another and then laminated on the reinforcement (8).

[0093] In this way, a PVC or acrylic or polyolefin Plastisol can be coated onto the resulting reinforced coating support and then gelified in order to obtain the decorative layer or sublayer of the multilayer structure.

[0094] A fiberglass grid can have the form of a grid or screen of textile yarns of negligible thickness, preferably, spaced from one another by 3 mm along the longitudinal and transverse dimensions and have a linear mass density of between 20 g/m and 70 g/m, advantageously between 35 g/m and 50 g/m.

[0095] With reference to FIG. 2, the presently described embodiments also relate to a multilayer structure (1) produced in the shape of a band, for the production of a heating floor or wall covering or similar, comprising a decorative layer (not shown), a heating layer and a lower sublayer (3) the heating layer (4) of which comprises a conductive band (4a) produced from a nonwoven textile comprising conductive particles homogeneously distributed on the surface and/or in the thickness of said conductive band (4a). The multilayer structure (1) is made in the form of a band and the conductive band (4a) extends along said band. The conductive band (4a) supports three conductive electrodes, respectively (5a, 5b, 5c), spaced from one another and configured so as to define a discontinuous heating surface. The heating surface thus extends over almost all of the surface, in the longitudinal and transverse directions, of the multilayer structure (1) thus formed.

[0096] In this way, a large size multilayer structure can be obtained while also limiting heating losses due to an excessive separation between the electrodes supported by the conductive band.

[0097] In order to heat the room in which the multilayer structure (1) is located, each electrode is connected to a direct or alternating current source (20) through two connectors (21a, 21b). The connection between the connectors and the electrodes can be done by any means which could establish and maintain electrical contact. As an example, a connector can in particular pass through the thickness of the multilayer structure opposite an electrode and be held by clipping, screwing or equivalent. Advantageously, a portion of the multilayer structure is disposed along an equipment duct or baseboard so as to mask the connectors in the equipment duct or the baseboard and protect them.

[0098] The resulting heating surface is considered as discontinuous to the extent where no heating is produced over the width of the conductive band supporting the conductive electrodes, in particular the electrode (5b). The electrodes are thus advantageously chosen with very narrow width, more advantageously in the form of conductive ribbons. Generally, the electrode (5b) will have a width greater than the width of electrodes (5a, 5c) so as to reduce the resistance thereof by increasing the cross section thereof. The electrode (5b) can be considered as a central electrode in so far as it is disposed between the electrodes (5a, 5c). The electrodes (5a, 5c) can be considered as lateral electrodes. In the example shown in FIG. 2, a positive electric potential is applied to the electrode (5b) and a negative potential is applied to the electrodes (5a, 5c). The current then flows in the parts of the conductive band (4a) disposed between the electrodes (5a, 5b) and (5b, Sc).

[0099] In order to achieve a regulated heating system, the direct-current source (20) can be controlled by a regulation system (30) connected to a temperature probe (40) disposed in the room to be heated or linked to the decorative layer or sublayer of the multilayer structure (1).

[0100] With reference to FIG. 3, a variant of embodiment of the multilayer structure (1) comprises a conductive band (4a) supporting at least two pairs of conductive electrodes (5a, 5b, 5a′, 5b′), said electrodes being spaced from one another and configured so as to define a discontinuous heating surface.

[0101] With reference to FIG. 4, the presently described embodiments also relate to a multilayer structure (1) according to FIG. 3 implemented in the shape of a band, for the production of a heating floor or wall covering or similar, comprising a decorative layer (not shown), a heating layer and a lower sublayer (3) the heating layer (4) of which comprises a conductive band (4a) produced from a nonwoven textile comprising conductive particles homogeneously distributed over the surface and/or in the thickness of said conductive band (4a). The multilayer structure (1) is made in the form of a band and the conductive band (4a) extends along said band. The conductive band (4a) supports two pairs of conductive electrodes (5a, 5b, 5a′, 5b′) spaced from one another and configured so as to define a discontinuous heating surface. The heating surface thus extends over almost all of the surface, in the longitudinal and transverse directions, of the multilayer structure (1) thus formed. The resulting heating surface is considered as discontinuous to the extent no heating is produced over the width of the conductive band supporting the conductive electrodes (5a, 5b, 5a′, 5b′). Similarly, if the same electric potential is applied to the two closest electrodes of each pair (5b, 5a′), no heating is obtained over the width of the conductive band disposed between the electrodes (5b, 5a′). The electrodes are thus advantageously chosen with very narrow width, more advantageously in the form of conductive ribbons.

[0102] With reference to FIG. 5, the presently described embodiments also relate to an alternative embodiment of the multilayer structure (1).

[0103] The multilayer structure (1) comprises an upper decorative layer (2) made up of at least one plastic surface layer (2a), bonded onto a heating layer (4), said heating layer (4) being bonded onto a lower sublayer (3) intended to be installed on the floor or a wall or the like. The heating layer is comprised of at least two conductive bands (4a, 4a′) disposed side-by-side and spaced from one another, said conductive bands (4a, 4a′) comprising conductive particles distributed homogeneously over the surface and/or in the thickness of said conductive bands (4a, 4a′), and each conductive band (4a, 4a′) supports two conductive electrodes (5a, 5b, 5a′, 5b′) spaced from one another so as to define a discontinuous heating surface.

[0104] The heating layer (4) is made up of two conductive bands (4a, 4a′) disposed side-by-side and spaced from one another. The conductive bands (4a, 4a′) are produced for example from a nonwoven textile impregnated with conductive particles, specifically fiberglass impregnated with carbon fibers, with a grammage of between 25 g/m.sup.2 and 80 g/m.sup.2, advantageously between 25 g/m.sup.2 and 40 g/m.sup.2. A conductive band produced from a nonwoven fiberglass textile impregnated with carbon fibers with a grammage of 30 g/m.sup.2 has a resistance of between 4 and 5 ohms over a distance of 40 cm.

[0105] Each conductive band (4a, 4a′) supports two conductive electrodes (5a, 5b, 5a′, 5b′) spaced from one another so as to define a discontinuous heating surface. The heating surface thus extends between each pair of electrodes supported by a single conductive band. Obviously, the grammage of the nonwoven textile of the conductive band and the quantity of conductive particles could be adjusted to obtain the desired resistivity value depending on the size of the heating surface.

[0106] The conductive electrodes (5a, 5b), (5a′, 5b′) are ribbons disposed along the longitudinal edges of the conductive bands (4a, 4b, 4a′, 4b′) such that the heating surface extends over almost all of the surface of the multilayer structure thus formed. The resulting heating surface extends between the electrodes (5a, 5b) and (5a′, 5b′). In the case of a structure (1) produced in the shape of a band, the heating surface extends in the longitudinal direction of the band thus produced and between the electrodes (5a, 5b) and (5a′, 5b′).

[0107] Alternatively, the electrodes (5b) and (5a′) are in electrical contact and are obtained for example from a single conductive ribbon. In this scenario, the electrical connections of the electrodes (5a) and (5b′) are then modified in order to keep two conductive bands (4a, 4a′) powered independently. A discontinuous heating surface with simpler implementation is defined by this configuration. The single electrode corresponding to electrodes (5b) and (5a′) is for example supplied with 24 Vdc and the electrodes (5a) and (5b′) are connected to ground.

[0108] The electrodes (5a, 5b, 5a′, 5b′) are for example ribbons made of a 40 μm thick copper strap. The electrodes (5a, 5b, 5a′, 5b′) are for example bonded onto each conductive band by a 25 μm thick layer of conductive adhesive.

[0109] In the case where each conductive band (4a, 4a′) is made of a nonwoven textile, said conductive bands can be used as a coating support in a fabrication method for the multilayer structure. For this purpose, each conductive band produced from a nonwoven textile (4a, 4a′) is disposed edge-to-edge and spaced from one another and then laminated in order to be arranged in contact with a single reinforcement (8), such as a fiberglass mat and/or a fiberglass grid. In this way a reinforced coating support can be obtained. The width of the reinforcement (8) is advantageously larger than the sum of the widths of the conductive bands disposed edge-to-edge in order to laminate the conductive bands over their entire width on the reinforcement. The electrodes (5a, 5b, 5a′, 5b′) are spaced from one another and then glued onto the conductive band (4a, 4a′). Alternatively the electrodes (5a, 5b, 5a′, 5b′) are spaced from one another and then bonded onto the reinforcement (8), then each conductive band (4a, 4a′) is disposed edge-to-edge and spaced from one another and then complexed onto the electrodes and the reinforcement (8).

[0110] In this way, a PVC or acrylic or polyolefin Plastisol can be coated onto the resulting reinforced coating support and then gelified in order to obtain the decorative layer or sublayer of the multilayer structure.

[0111] With reference to FIG. 6, the presently described embodiments also relate to a multilayer structure (1) produced in the shape of a band, for the production of a heating floor or wall covering or similar, comprising a decorative layer (not shown), a heating layer and a lower sublayer (3) the heating layer (4) of which comprises three conductive bands (4a, 4a′, 4a″) produced in a nonwoven textile comprising conductive particles homogeneously distributed over the surface and/or in the thickness of said conductive band (4a, 4a′, 4a″). The conductive bands (4a, 4a′, 4a″) are disposed side-by-side and spaced from one another. The multilayer structure (1) is made in the form of a band and the conductive bands (4a, 4a′, 4a″) extend along said band. Each conductive band (4a, 4a′, 4a″) supports two conductive electrodes (5a, 5b), (5a′, 5b′) and (5a″, 5b″) spaced from one another so as to define a discontinuous heating surface. The heating surface thus extends over almost all of the surface, in the longitudinal and transverse directions, of the multilayer structure (1) thus formed.

[0112] In this way, a very wide multilayer structure, preferably over 1.20 m, can be obtained while also limiting heating losses due to an excessive separation between the electrodes supported by a single conductive band. In fact, it is undesirable to have the distance between two conductive electrodes of a single conductive band greater than 50 cm, since the current necessary to heat said conductive band is directly proportional to the separation and quickly reaches dangerous electrical powers in inhabited rooms.

[0113] Still according to FIG. 6, a multilayer structure (1) is produced for example in the form of a band about 1.20 m wide comprising three conductive bands (4a, 4a′, 4a″) made of a nonwoven textile with a grammage of 30 g/m.sup.2 with fiberglass impregnated with carbon fibers, with each band measuring 40 cm wide. The bands are disposed side by side and spaced from one another in order to obtain a heating surface about 1.20 m wide. Each conductive band supports two copper ribbons 1 cm wide and 45 μm thick, spaced from one another and glued onto the conductive band with a 25 μm layer of conductive adhesive. A few millimeters are left between the conductive electrodes (5b, 5a′) and (5b′, 5a″) in order to limit the risks of a short circuit.

[0114] For a conductive band made of a nonwoven textile, with a grammage of 30 g/m.sup.2 of glass fibers impregnated with carbon fibers, 40 cm wide and 300 cm long, the measured resistance is between 4 and 5 ohms between two electrodes supported by a single conductive band. In that way, with a 24 Vdc source, a heating power of 109 W is obtained over the surface between two electrodes of a single conductive band over a width of 40 cm and a length of 300 cm. With a 36 V source, a 236 W heating power is obtained.

[0115] With reference to FIG. 7, the heating multilayer structure (1) according to FIG. 6 is shown schematically installed in crowded rooms with obstacles (50, 51) requiring cutting operations. In the example shown, it is necessary to cut a part of the multilayer structure in order to go around the obstacles (50, 51). By doing this cutting, a part of the heating layer is made unusable, for example because of cutting the electrode 5b″. It is, however, still possible to heat the room in which the multilayer structure is installed by supplying the conductive electrodes (5a′, 5b′) supported by the conductive band (4a′). The other conductive bands (4a, 4a″) could also be supplied by their own electrodes in order to heat the surfaces facing each of these electrodes (4a, 4a″); the resulting heating surface is however reduced.

[0116] With reference to FIG. 8, the presently described embodiments also relate to a multilayer structure (1) produced in the shape of a band, for the production of a heating floor or wall covering or similar, comprising a decorative layer (not shown), a heating layer and a lower sublayer (3) the heating layer of which comprises three conductive bands (4a, 4a′, 4a″) comprising conductive particles homogeneously distributed over the surface and/or in the thickness of said conductive band (4a, 4a′, 4a″). The conductive bands (4a, 4a′, 4a″) are disposed side-by-side and spaced from one another. The multilayer structure (1) is made in the form of a band and the conductive bands (4a, 4a′, 4a″) extend transversally to said band. Each conductive band (4a, 4a′, 4a″) supports two conductive electrodes (5a, 5b), (5a′, 5b′) and (5a″, 5b″) spaced from one another so as to define a discontinuous heating surface.

[0117] Preferably, and whatever the embodiment, the heating layer (4) comprises a dielectric layer (6) bonded onto the decorative layer (2) and a dielectric layer (7) bonded onto the sublayer (3) in order to electrically insulate this layer from the other layers of the multilayer structure. The conductive bands (4a, 4a′) and also the electrodes (5a, 5b, 5c, 5a′, 5b′, 5a″, 5b″) that they support are thus sandwiched between two dielectric layers (6, 7). A dielectric layer can in particular be obtained from a sheet of PVC, polyethylene terephthalate (PET) or any other nonconductive polymer and bonded by thermal bonding for example.

[0118] A dielectric layer can also serve as support for implementation of the heating layer. For this purpose, each conductive band, for example a conductive band produced from a nonwoven textile, is disposed edge-to-edge and spaced from one another and then cold laminated with a dielectric layer (7) serving as support. The electrodes are subsequently spaced from one another and then bonded onto each conductive band. Advantageously, a second dielectric layer (6) is bonded onto each conductive band so as to sandwich the two conductive bands, and the electrodes that they support, between the dielectric layers (6) and (7) and to obtain an assembly which can be directly laminated with a decorative layer and a sublayer.

[0119] Advantageously, and whatever the embodiment, the heating layer (4) may comprise a reinforcement (8) bonded onto the decorative layer (2) and/or bonded onto the sublayer (3) arranged in contact with the one or more conductive bands (4a, 4a′, 4a″). The mechanical performance of the floor or wall coating and its resistance to indentation and to rolling can in particular be increased by a reinforcement (8). The reinforcement also provides dimensional stability of the covering over time.

[0120] From the preceding it can be seen that the presently described embodiments provide a multilayer structure (1) for the production of a heating floor or wall covering or similar, installed bonded, semi-floating or floating, thus achieving high classification levels in terms of resistance to traffic and impermeability, while guaranteeing a quick, inexensive renovation of a room, without disruption and and which incorporates efficient heating functions.