METHODS TO PROVIDE A FLOOR COVERING

Abstract

A method to provide a floor covering, including the steps of: providing a sheet vinyl; providing a PVC intermediate including at least a first layer of PVC material and at least a first reinforcing sheet, the first layer of PVC material providing the upper side of the PVC intermediate. The method also includes adhering the sheet vinyl to the PVC intermediate by laminating the lower side of the sheet vinyl to the upper side of the PVC intermediate.

Claims

1-18. (canceled)

19. A method to provide a floor covering, comprising the steps of: providing a sheet vinyl; providing a PVC intermediate comprising at least a first layer of PVC material and at least a first reinforcing sheet, the first layer of PVC material providing the upper side of the PVC intermediate; adhering said sheet vinyl to the PVC intermediate by laminating the lower side of the sheet vinyl to the upper side of the PVC intermediate.

20. The method of claim 19, wherein the sheet vinyl comprises at least a sequence of layers being: a lower reinforced PVC layer providing the lower side of the sheet vinyl; a decorative layer contacting the reinforced PVC lower layer; a wear layer contacting the decorative layer.

21. The method of claim 20, wherein the method comprises the step of embossing at least wear layer after said lamination step.

22. The method of claim 19, wherein the PVC material of the PVC intermediate comprises foamed PVC.

23. The method of claim 19, wherein the PVC material of the PVC intermediate comprises non-foamed PVC material.

24. The method of claim 19, wherein said PVC material of the PVC intermediate comprises semi-rigid or rigid PVC material.

25. The method of claim 19, wherein the PVC material present in the PVC intermediate is extruded PVC material.

26. The method of claim 25, wherein the extruded PVC intermediate is provided by extruding the first layer of extruded PVC material on one side of the at least one reinforcement sheet.

27. The method of claim 25, wherein the extruded PVC intermediate comprises two layers of extruded PVC material, the first layer of extruded PVC material is provided by extruding PVC material on a first side of the reinforcement sheet, the second layer of extruded PVC material being provided by extruding PVC material to the second side of the reinforcement sheet.

28. The method of claim 27, wherein the extruded PVC intermediate comprises at least a first and a second reinforcing sheet, the method comprises the steps of providing the first layer of extruded PVC material by extruding PVC material on a first side of the first reinforcement sheet, providing the second layer of extruded PVC material by extruding PVC material to the second side of the first reinforcement sheet and on a first side of the second reinforcing sheet.

29. The method of claim 28, wherein the first layer of extruded PVC material is a multilayered stack of two co-extruded PVC sublayers, obtained by co-extrusion of a first PVC material providing the first of the two sublayers, and a second PVC material providing the second of the two sublayers, the second layer of extruded PVC material is a multilayered stack of two co-extruded PVC sublayers, obtained by co-extrusion of a third PVC material providing the first of the two sublayers, and a fourth PVC material providing the second of the two sublayers, and wherein the second of the two sublayers of the first layer of extruded PVC material is in contact with the first of the two sublayers of the second layer of extruded PVC material, optionally in contact through the first reinforcing sheet; the first and fourth PVC material are identical and the second and third PVC material are identical.

30. The method of claim 19, wherein the PVC intermediate is provided by providing PVC granulate, said granulates consisting of PVC material; providing the first reinforcing sheet; deposit the first reinforcing sheet on a transporting device; strewing said PVC granulate on said first reinforcing sheet; passing said PVC granulate by the transporting device along a heating means for heating said PVC granulate on said first reinforcing sheet; passing said heated PVC granulate by the transporting device along a continuous pressing device for consolidating said PVC granulate thereby providing the PVC intermediate; optionally cooling said PVC intermediate.

31. The method of claim 30, wherein the PVC intermediate comprises at least a first and a second reinforcing sheet, the method comprises the step of providing the second reinforcing sheet prior to the strewing of the PVC granulates of a first PVC material on the transporting device.

32. The method of claim 30, wherein the PVC intermediate comprises two layers of PVC material, each of the two layers being a multilayered stack of at least two PVC sublayers, the method comprising the steps of strewing PVC granulates of a first PVC material on the transporting device to provide the second sublayer of the second layer of PVC material; strewing PVC granulates of a second PVC material on the strewn first PVC material on the transporting device to provide the first sublayer of the second layer of PVC material; providing the first reinforcing sheet on the strewn second PVC material on the transporting device; strewing PVC granulates of a third PVC material on the first reinforcing sheet on the transporting device to provide the second sublayer of the first layer of PVC material; strewing PVC granulates of a fourth PVC material on the strewn third PVC material on the transporting device to provide the first sublayer of the first layer of PVC material; optionally providing the second reinforcing sheet prior to the strewing of the PVC granulates of a first PVC material on the transporting device wherein optionally the first and fourth PVC material are identical and the second and third PVC material are identical.

33. The method of claim 29, wherein the first and fourth PVC material is non-foamed preferably rigid PVC material, the second and third PVC material being foamed, preferably rigid or semi-rigid PVC material.

34. The method of claim 19, wherein said lamination is thermal lamination.

35. The method of claim 19, wherein said sheet vinyl is unembossed prior to said lamination.

36. A method to provide a floor covering element, comprising the steps of providing a floor covering according to claim 19; dividing the floor covering in at least two floor covering elements.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0105] FIG. 1 is a schematically view of production method according to the invention.

[0106] FIG. 2 is schematically view of a cross section of a product obtainable by the method as shown in FIG. 1.

[0107] FIG. 3 is a schematically view of an alternative production method according to the invention.

[0108] FIGS. 4 and 5 are schematically views of a cross section of a product obtainable by the method according to the invention.

[0109] FIG. 6 is a schematically view of an alternative production method according to the invention.

[0110] FIG. 7 is a schematically view of a cross section of a product obtainable by the method according to the invention.

[0111] FIG. 8 is a schematically view of an alternative production method according to the invention.

[0112] FIG. 9 is a schematically view of a cross section of a product obtainable by the method according to the invention.

[0113] FIG. 10 is a schematically view of an alternative production method according to the invention.

[0114] The same reference signs refer to the same, similar or analogous elements in the different figures.

DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

[0115] The present invention will be described with respect to particular embodiments. It is to be noticed that the term “comprising”, used in the claims, should not be interpreted as being restricted to the means listed thereafter; it does not exclude other elements or steps. It is thus to be interpreted as specifying the presence of the stated features, steps or components as referred to, but does not preclude the presence or addition of one or more other features, steps or components, or groups thereof. Thus, the scope of the expression “a device comprising means A and B” should not be limited to devices consisting only of components A and B. It means that with respect to the present invention, the only relevant components of the device are A and B.

[0116] Throughout this specification, reference to “one embodiment” or “an embodiment” are made. Such references indicate that a particular feature, described in relation to 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, though they could.

[0117] Furthermore, the particular features or characteristics may be combined in any suitable manner in one or more embodiments, as would be apparent to one of ordinary skill in the art.

[0118] When in this document reference is made to rigid PVC, this refers to PVC comprising less than 6 phr plasticizer. When reference is made to semi-rigid PVC, this refers to PVC comprising plasticizer in a range of 6 to 12 phr. When reference is made to flexible PVC, this PVC comprises more than 12 phr.

[0119] As is shown in FIGS. 1 and 3, a sheet vinyl 100 is provided, here in the form of a roll of sheet vinyl 101. The sheet vinyl, as shown in FIGS. 2, 4 and 5, this sheet vinyl comprises: [0120] A lower reinforced PVC layer 14, comprising PVC material and a reinforcing element being a glass fiber woven or nonwoven sheet 15; [0121] A decorative layer 13 contacting the PVC lower layer; [0122] A wear layer 12 contacting the decorative layer; [0123] A top coat layer 11 contacting the wear layer and providing the upper surface of the sheet vinyl

[0124] The method to provide a floor covering 500 is schematically shown in FIG. 1. The method comprises the steps of: [0125] Providing a sheet vinyl 100; [0126] Providing, by means of a extruder 206, an extruded PVC intermediate 200 comprising PVC material 202 and a reinforcing sheet 204.

[0127] The sheet vinyl 100 and the extruded PVC intermediate 200 are adhered to each other via lamination. The lower surface 113 of the sheet vinyl 100 is laminated to the upper side 213 of the extruded PVC intermediate 200. One or both of the mutually facing surfaces of the sheet vinyl and the extruded PVC intermediate, which are to be adhered to each other, may first be heated by means of a heating device 250. Prior to heating, the thickness of the extruded PVC intermediate 200 may be calibrated in thickness by a calibration device, e.g. a set of calibration rollers 240. The sheet vinyl 100 and the extruded PVC intermediate 200 are laminated using a lamination device 300.

[0128] This intermediate product may be embossed by embossing roll 350. Optionally, the surface provided by the top coat layer may first be heated by a heating device, e.g. an IR heater 400, prior to embossing. The embossing may be in register or not in register with the decorative pattern or figure visible in the decorative layer.

[0129] After embossing, the floor covering 500 may be cut in individual floor covering elements 550 by a cutting installation 450. Typically the floor covering elements 550 have a rectangular circumference. These floor covering elements may thereafter be foreseen from coupling means at at least two mutually opposing sides, optionally at four sides, by the conventional and well known methods of grinding and milling.

[0130] In FIG. 1, the PVC 202 is extruded on one side of the reinforcing sheet 204. The reinforcing sheet 204 functions, when the floor coveting 500 is in use, as a balance sheet or balance layer to compensate for the presence of the reinforcing element 15 of the sheet vinyl used.

[0131] As shown in FIG. 2, the product obtained by the method as shown in FIG. 1, is a layered structure where the reinforcing sheet 204 is provided at the lower surface 502 of the floor covering 500 obtained. The upper surface 501 is provided by the embossed top coat layer 11 of the sheet vinyl 100.

[0132] An alternative method is shown in FIG. 3. Same references refer to similar or even identical elements. In this embodiment, two layers 212 and 222 of extruded PVC material are provided by mean of two extruders 216 and 226, the reinforcing sheet 204 being positioned about in the middle of the two layers of extruded PVC material. These two layers of extruded PVC together with the reinforcing layer 204 together for the extruded PVC intermediate 200. A floor covering 600 and floor covering elements 650 are provided. A cross section is shown in FIG. 4.

[0133] The two layers of extruded PVC 212 and 222 may be provided from identical or from different PVC material.

[0134] Again, the reinforcing sheet 204 functions, when the floor coveting 500 is in use, as a balance sheet or balance layer to compensate for the presence of the reinforcing element 15 of the sheet vinyl used.

[0135] In still another embodiment, a cross section being shown in FIG. 5, a similar floor covering 700 is shown, where the reinforcing sheet 204 is positioned out of center of the extruded PVC intermediate 200. In this embodiment, the reinforcing sheet 204 is located closer to the lower surface 702 of the floor covering 700.

[0136] In even another embodiment, a cross section being shown in FIG. 7, a similar floor covering 800 is shown, where the extruded PVC intermediate comprises two reinforcing sheets 204 and 244. The reinforcing sheet 204 is positioned in center of the extruded PVC intermediate 200, however it may be positioned our of center as well, i.e. closed or further away from the reinforcing layer 244. This layer 244 is positioned at the lowed surface of the extruded PVC intermediate 200.

[0137] A schematically view of the method is provided in FIG. 6. As is clear, the second layer of extruded PVC material 222 is extruded between the two reinforcing sheets 204 and 244.

[0138] To obtain this embodiment, the extruded PVC material of layer 222 is extruded on the reinforcing sheet 244 and combined with the extruded PVC material of layer 212 being extruded on the reinforcing sheet 204.

[0139] In all these embodiments, the PVC material to provide the extruded PVC intermediates are rigid PVC materials. When various layers of extruded PVC are used, the materials to provide the layers may be identical or different.

[0140] Similarly, in all these embodiments, the PVC material to provide the extruded PVC intermediates are non-foamed PVC materials. Some or all of them may be replaced by foamed PVC materials. When various layers of extruded PVC are used, the materials to provide the layers may be identical or different in foaming structure.

[0141] Most preferred PVC material is a copolymer of vinylchloride and vinyl acetate, with K value 57 is used for the layers of extruded PVC material. The material is plasticizer free and comprises 40% w of filler.

[0142] As reinforcing sheet for the layers of extruded PVC material is a glass fiber nonwoven sheet, impregnated with 2 abut 20% w of binder, and having a surface weight of 120 g/m.sup.2.

[0143] The thickness of the extruded PVC intermediate 200 is about 3 mm.

[0144] The PVC material used in the sheet vinyl preferably is flexible PVC.

[0145] The reinforcing element of the sheet vinyl may be identic to the reinforcing sheet of the extruded PVC intermediate.

[0146] The thickness of the sheet vinyl 100 may be about 1 mm.

[0147] When the floor covering is separated in individual floor covering elements, such elements typically have a rectangular circumference, with basis of about 1.32 m and a height of about 23 cm.

[0148] An alternative method is shown in FIG. 8. Same references refer to similar or even identical elements. In this embodiment, two layers 232 and 242 of extruded PVC material are provided by mean of two extruders 236 and 246, the reinforcing sheet 204 being positioned about in the middle of the two layers of extruded PVC material. The first layer 232 of extruded PVC material, being extruded on the first reinforcing sheet 204, is a stack of two co-extruded sublayers 232a and 232b. The second layer 232 of extruded PVC material, being extruded between the first reinforcing sheet 204 an the second reinforcing sheet 244, is a stack of two co-extruded sublayers 242a and 242b. for the extrusion, an extruder 236 and 246 fit for extruding two layers one on top of the other, is used. The composition of the PVC material of sublayer 242a and 232b are identical. Preferably a rigid PVC which is foamed is used. The composition of the PVC material of sublayer 242b and 232a are also identical. Preferably a rigid PVC which is not foamed is used.

[0149] These two layers of extruded PVC together with the reinforcing layers 204 and 244 together for the extruded PVC intermediate 200. A floor covering 900 and floor covering elements 950 are provided. A cross section is shown in FIG. 9.

[0150] The two layers of extruded PVC 212 and 222 may be provided from identical or from different PVC material.

[0151] The co-extruders 236 and 246 may be provided such that they extrude sublayer 232b respectively 242b being encompasses (contacted at both sides) by PVC material providing layer 232a respectively 242a. as such each of the two layers of extruded PVC material, becomes a multiple stack of 3 layers of extruded PVC material.

[0152] An alternative method to provide a floor covering is shown in FIG. 10. The floor covering obtained has the same composition as the floor covering 900 of FIG. 9.

[0153] Again the PVC intermediate comprises two layers of PVC material, each of the two layers being a multilayered stack of at least two PVC sublayers.

[0154] The method comprising the steps of [0155] providing the second reinforcing sheet 244 on the transporting device [0156] strewing PVC granulates 1242b of a first PVC material on the transporting device 2001 to provide the second sublayer 242b of the second layer 242 of PVC material; [0157] strewing PVC granulates 1242a of a second PVC material on the strewn first PVC material 1242b on the transporting device 2001 to provide the first sublayer 242a of the second layer 242 of PVC material; [0158] providing the first reinforcing sheet 204 on the strewn second PVC material 1242a on the transporting device 2001; [0159] strewing PVC granulates 1232b of a third PVC material on the first reinforcing sheet 204 on the transporting device 2001 to provide the second sublayer 232b of the first layer 232 of PVC material; [0160] strewing PVC granulates 1232a of a fourth PVC material on the strewn third PVC material 1232b on the transporting device 2001 to provide the first sublayer 232a of the first layer 232 of PVC material;

[0161] Once all these PVC granulates are strewn, a second transporting device 2002 sandwiches all the strewn granulates and reinforcing sheets between it and the first transporting device 2001.

[0162] From bottom and top, the sandwiched material is heated to melt the PVC granulates by a heating means 2003. The molten sandwiched material is compressed by a set of rollers 2004, which may be a so-called S-curve pressing device, or a steel belt press 2005 or as shown in FIG. 10, by both a set of rollers and a steel belt press. The compressed sandwiched material is cooled by a cooling device 2006.

[0163] By means of a heating device 205 the upper surface of the PVC intermediate is heated, as well as the lower side of the sheet vinyl 100. By thermal lamination in laminator 300 the sheet vinyl and the PVC intermediate are combined, and the combination is embossed by embossing roll 350 to provide the floor covering 900.

[0164] It is to be understood that although preferred embodiments and/or materials have been discussed for providing embodiments according to the present invention, various modifications or changes may be made without departing from the scope and spirit of this invention.