FLOOR, WALL AND CEILING CLADDING

Abstract

The present disclosure relates to a floor, wall and ceiling cladding for protection, damping and insulation purposes, comprising a combination of a support layer building board having a first surface and a second surface, said support layer building board comprising a lightweight building board, of a first top coating arranged on the first surface, said first top coating comprising a polyurethane, a polyurea and/or epoxy resin, and of an adhesive fastening arranged on the second surface. The present invention further relates to a method for producing a floor, wall and ceiling cladding.

Claims

1. A floor, wall, and ceiling cladding for protection, damping and insulation purposes, wherein a combination is comprised of a support layer having a first surface and a second surface, wherein the support layer comprises a lightweight building board, a first top coating arranged on the first surface, said first top coating comprising a polyurethane, polyurea and/or epoxy resin, and an adhesive fastening arranged on the second surface.

2. The floor, wall, and ceiling cladding of claim 1 wherein the lightweight building board comprises materials selected from the group comprising plastics, lightweight metals, fibre-reinforced composites or any combination thereof.

3. The floor, wall and ceiling cladding of claim 1 wherein a second top coating is arranged on the first top coating.

4. The floor, wall, and ceiling of claim 1 wherein the lightweight building board comprises a polymer encased between two aluminum layers.

5. The floor, wall, and ceiling of claim 1 wherein the lightweight building board comprises a polymer foam encased between two aluminum layers.

6. The floor, wall, and ceiling cladding according to claim 5, wherein the polymer foam is a polypropylene foam or a polyethylene foam.

7. The floor, wall, and ceiling cladding of claim 1 wherein the strength properties of the lightweight building board are higher than the strength properties of the first top coating.

8. The floor, wall, and ceiling cladding of claim 1 wherein the first top coating has an anti-slip coefficient of at least R10.

9. The floor, wall, and ceiling cladding of claim 1 wherein the first top coating has an slide-friction coefficient of at least 0.6 μD.

10. The floor, wall, and ceiling cladding of claim 1 wherein the first top coating has an outer surface that is smooth, rough or structured.

11. The floor, wall, and ceiling cladding of claim 1 wherein the first top coating and/or a second top coating comprises nano-parts coated with a wax-like layer for providing a hydrophobic surface.

12. The floor, wall, and ceiling cladding of claim 1 wherein the first top coating and/or a second top coating comprises bound silver ions, copper ions and/or terbutryn.

13. The floor, wall, and ceiling cladding of claim 1 wherein the first top coating and/or a second top coating comprises a fabric consisting in aluminium, stainless steel, copper or carbon fibres.

14. The floor, wall, and ceiling cladding of claim 1 wherein the first top coating and/or a second top coating comprises soot particles or electrically conductive fibres.

15. The floor, wall, and ceiling cladding of claim 1 wherein the adhesive fastening comprises a backing-based adhesive tape, a transfer adhesive tape or a liquid adhesive.

16. The floor, wall, and ceiling cladding of claim 1 wherein the backing-based adhesive tape comprises a soft elastic backing.

17. The floor, wall, and ceiling cladding of claim 1 wherein the adhesive fastening comprises acrylate, polyurethane, epoxies, silicone and/or natural rubber.

18. The floor, wall, and ceiling cladding of claim 1 wherein a tear off film is arranged on one outer surface of the adhesive fastening.

19. The floor, wall, and ceiling cladding of claim 1 wherein an additional fastening means is integrated in the layer design of the first top coating, the support layer, and/or the adhesive fastening, for fastening the floor, wall, and ceiling cladding to a floor, a wall, or a ceiling.

20. The floor, wall, and ceiling cladding of claim 1 wherein at least one transponder is integrated in the support layer of the first top coating, preferably an RFID transponder.

21. The floor, wall and ceiling cladding of claim 1 wherein at least one line is integrated in the support layer of the first top coating, preferably an electric line.

22. The floor, wall, and ceiling cladding for to claim 1, wherein the floor, wall, and ceiling cladding are configured as a wall element.

23. The floor, wall, and ceiling cladding of claim 1, wherein the floor, wall, and ceiling cladding are configured as an adhesive tile.

24. The floor, wall, and ceiling cladding of claim 1, wherein the floor, wall, and ceiling cladding are configured as a floor element.

25. The floor, wall, and ceiling cladding of claim 1, wherein the floor, wall, and ceiling cladding are configured as a ceiling element.

26. A method for manufacturing a floor, wall and ceiling cladding of claim 1, comprising: providing the support layer, applying the adhesive fastening on the second surface of the support layer (2), and coating the first surface of the support layer with the first top coating using a spraying or casting method.

27. The method for producing a floor, wall, and ceiling cladding of claim 26, wherein when coating the support layer with the first top coating, solid bodies such as hard grain are sprayed or cast together with the coating.

28. The method for manufacturing a motor or utility vehicle supporting device of claim 26, wherein a final spray coating step the spray coat is applied from a distance calculated such that a sprayed-on plastics starts reacting before it reaches the first top coating or a second top coating (30), thus producing an uneven surface on the first top coating or the second top coating (30).

Description

BRIEF DESCRIPTION OF THE FIGURES

[0054] Preferred embodiments of the invention are illustrated in further detail by the subsequent description of the Figures. In this:

[0055] FIG. 1 shows a schematic sectional view of the layer configuration of a floor, wall and ceiling cladding,

[0056] FIG. 2 shows a schematic sectional view of the floor, wall and ceiling cladding of FIG. 1 with a tear-off film,

[0057] FIG. 3 shows a schematic sectional view of a floor, wall and ceiling cladding, comprising a lightweight building board consisting in a polymer foam encased between two aluminium layers,

[0058] FIG. 4 shows a schematic sectional view of the floor, wall and ceiling cladding of FIG. 3 in a state where it is applied to an uneven surface,

[0059] FIG. 5 shows a schematic sectional view of the floor, wall and ceiling cladding including a backing-based adhesive tape,

[0060] FIG. 6 shows a schematic sectional view of the floor, wall and ceiling cladding of FIG. 5 on an uneven surface,

[0061] FIG. 7 shows a schematic sectional view of the floor, wall and ceiling cladding with three adhesive layers,

[0062] FIG. 8 shows a schematic sectional view of the floor, wall and ceiling cladding with adhesive layers adapted to the support layer, and

[0063] FIG. 9 shows a schematic sectional view of the floor, wall and ceiling cladding including an adhesive layer comprising two backings.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

[0064] Preferred embodiments based on the Figures are described hereinafter. In this, identical or similar elements or elements with the same effect are referenced with identical reference numerals in the different Figures, and these elements are not repeatedly described so as to avoid redundancies.

[0065] FIG. 1 shows a sectional view of a floor, wall and ceiling cladding 1. The floor, wall and ceiling cladding 1 consists in a layered configuration, including a support layer (2) in the form of a lightweight building board. In the case in hand, the lightweight building board is made of aluminium. Alternatively, the lightweight building board also can be made of plastic. Made from the plastics. For example, lightweight building boards made of fibre composites can be used, such as reinforcing fibres embedded in a polymer matrix. Carbon fibres, glass fibres, plastic fibres, natural fibres and/or metal fibres can be used as reinforcing fibres.

[0066] Support layer 2 has a first surface 20 and a second surface 22. The first surface 20 is coated with a first top coating 3. The first top coating can me made of epoxy resin, polyurethane or polyurea, which originally are sprayed on the first surface 20 of the support layer 2 in the form of a resin curing agent mixture. For the embodiment in hand, the solvent-free two-component reactive spray coating VIASEAL LCT1616-60 by the company VIACOR Polymer GmbH is used. It has excellent resilient properties and serves as an anti-slip coating. The cured product has a tensile strength of at least 11 N/mm.sup.2 (DIN 53504), elongation at break of at least 300% (DIN 53504) and a shore-A hardness of ca. 88 (5 d/23° C.) (DIN EN ISO 868). Moreover, when spraying the first top coating 3 onto the first surface 20 hard grain can be included so as to increase roughness of a first outer surface of the first top coating 3. In the latter case, alternatively, also the solvent-free two-component reactive spray VIASEAL LCT1622-60 by the company VIACOR Polymer GmbH can be used as a first top coating. It is comparatively harder and is thus well-suited for incorporating granulate such as, for example, hard grain.

[0067] The combination consisting in the support layer 2 and the first top coating 3 is resistant to high mechanical loads and large temperature differences. Moreover, the bond between the support layer 2 and the first top coating 3 withstands strong deformations, too.

[0068] An adhesive fastening 4 is arranged on the second surface 22 of the support layer 2 in the form of a backing-based adhesive tape, whereas the backing comprises a soft foam. By way of the adhesive fastening (4), the floor, wall and ceiling cladding can be glued to the respective site of use. In the alternative, the adhesive fastening can also comprise a transfer adhesive tape, i.e. a tape without backing. Thus, due to the resilience properties of the adhesive fastening, irregularities in the surface elements are to be affixed to can be levelled out.

[0069] Walls, ceilings and floors can be functionalised by applying the floor, wall and ceiling cladding. This also comprises protective functions such as for example noise and thermal insulation or impact protection, moreover, anti-slip or slide-enhancing properties can be provided retroactively. In order to equip the walls, ceilings and floors with the above properties, the floor, wall and ceiling cladding 1 can be installed as finished products requiring just a few work steps.

[0070] The support layer (2) in the form of an aluminium lightweight building board gives the wall and ceiling cladding sufficient hardness and stiffness properties whilst keeping its weight relatively low. By way of the adhesive fastening (4), the floor, wall and ceiling cladding can be fastened to various walls, ceilings or floors. By way of example: concrete walls, ceilings and floors, plastered walls, wooden walls, wooden ceilings and wooden floors, etc.

[0071] FIG. 2 shows the floor, wall and ceiling cladding from FIG. 1, additionally including a tear-off film (5) on the outer surface of the adhesive fastening 4. The tear-off film 5 can remain on the adhesive fastening (4) just up until the floor, wall and ceiling cladding is installed.

[0072] FIG. 3 shows a schematic sectional view of a layer construction of a floor, wall and ceiling cladding (1) including a support layer (2) in the form of a lightweight building board comprising a polymer foam 24 encased between two aluminium layers. The polymer foam 24 is made of polypropylene, which is characterised by particularly low density. A support layer 2, consisting in two aluminium layers 26, 26′ and a polypropylene polymer foam layer encased in between these layers is characterised by high strength and comparatively low weight and small layer thickness.

[0073] Moreover, the polymer foam 24 comes with the advantage that it is malleable. For example, the floor, wall and ceiling cladding (1) can be assembled seamlessly across corners such as the transitional area between the floor and a wall. Moreover, the polymer foam (24) encased between the aluminium layers (26), (26′) is characterised by good thermal insulation properties. The adhesive fastening (4) shown in FIG. 3 is formed by a transfer adhesive tape and is glued to the side of the aluminium layer 26′ facing away from the polymer foam (24).

[0074] FIG. 4 shows the floor, wall and ceiling cladding (1) from FIG. 3, whereas the adhesive fastening (4) compensates for unevenness of the surface (6) of the ceiling or the floor. Such an uneven surface (6) may for example also be caused by a plaster layer on a wall. The adhesive fastening (4) is a transfer adhesive tape. In FIG. 4, unevenness is shown as protrusions (60). The adhesive fastening (4) thus allows for almost constant performance of the floor, wall and ceiling cladding, regardless of the condition of the surface.

[0075] FIG. 5 shows a floor, wall and ceiling cladding (1) similar to the floor, wall and ceiling cladding shown in FIG. 3. In contrast to the transfer adhesive tape shown in FIG. 3 the floor, wall and ceiling cladding (1) shown in FIG. 5 includes adhesive fastening (4) in the form of a backing-based adhesive tape. The backing-based adhesive tape forms a double-sided adhesive tape, comprising a first adhesive layer (40), a backing (42) and a second adhesive layer (44). The backing (42) is arranged between the first adhesive layer (4) and the second adhesive layer (44). The first adhesive layer (40) abuts the aluminium layer (26′) of the backing layer (2). A tear-off film (5) is arranged on the bottom surface of the second adhesive layer (44).

[0076] Moreover, the floor, wall and ceiling cladding (1) shown in FIG. 5 includes a second top coating (30) on the first top coating (3). The second top coating may for example provide an additional function and apart from polyurethane, polyurea and/or epoxy resin may for example include further functional materials. For example, the second layer may include soot particles or electrically conductive fibres in order to give the surface of the floor, wall and ceiling cladding (1) increased electric conductivity.

[0077] FIG. 6 shows the floor, wall and ceiling cladding (1) from FIG. 5, whereas the adhesive fastening (4) compensates for unevenness of the surface (6) of a wall, ceiling or floor. The floor, wall and ceiling cladding (1) is glued to the surface (6) and therefore no longer includes the tear-off film.

[0078] The protrusions (60) protruding from the surface (6) are compensated for by the adhesive fastening (4). The second adhesive layer (44) follows the profile of the surface (6). The thickness of the second adhesive layer (44) remains almost constant. The backing (42), in turn, is compressed in the areas of the protrusions (60). Thus it is possible to install the floor, wall and ceiling cladding (1) also on uneven, for example serrated surfaces without the adhesive bond between the floor, wall and ceiling cladding (1) and the surface (6) being compromised.

[0079] FIG. 7 shows a floor, wall and ceiling cladding (1) similar to the floor, wall and ceiling cladding shown in FIG. 5. The adhesive fastening (4) deviates from the adhesive layer shown in FIG. 5 in that it comprises an additional adhesive layer between the backing layer (2) and the backing (42). In particular, a first adhesive layer (40) is adapted to the requirements associated with creating an adhesive bond with the aluminium layer (26) and an adjacent third adhesive layer (46) is adapted to the requirements associated with creating an adhesive bond with the backing 42. By selecting the corresponding first and third adhesive layers (40), (46) depending on the materials of the support layer (2) and the backing (42), high-grade adhesion can be achieved, i.e. optimal cohesion of the compound can be ensured. A second adhesive layer (44) is applied on the bottom surface of the backing (42). In its non-assembled state, the bottom side of the adhesive fastening (4) is sealed with a tear-off film (5).

[0080] FIG. 8 shows a floor, wall and ceiling cladding (1) according to FIG. 5 with the only difference that the bottom surface of the support layer 2 exhibits different materials. One glass fibre layer (27′) is arranged alternating with a carbon fibre layer (28). Moreover, the adhesive fastening (4) is adapted to the different material pairing of the support layer (2) so that a first adhesive layer (40) contacts the glass fibre layer (27′) and a third adhesive layer (46) contacts the carbon fibre layer (28). By selecting the corresponding first and third adhesive layers (40), (46) depending on the materials of the support layer (2), high-grade adhesion can be achieved, i.e. optimal cohesion of the compound can be ensured. A second adhesive layer (44) is applied on the bottom surface of the backing (42). In its non-assembled state, the bottom side of the adhesive fastening (4) is sealed with a tear-off film (5).

[0081] FIG. 9 shows a floor, wall and ceiling cladding (1) according to FIG. 6 with the only difference that the adhesive fastening (4) comprises another backing (43) and a third adhesive layer (46). The adhesive fastening (4) has the following layer sequence: first adhesive layer (40), backing (42), second adhesive layer (44), backing (43) and third adhesive layer. The protrusions (60) protruding from the surface (6) are compensated for by the adhesive fastening (4). The second and third adhesive layers (44), (46) follow the profile of the surface (6). The thickness of the second and third adhesive layers (44), (46) remains almost constant. The backings (42), (43) in turn, are compressed in the areas of the protrusions (60).

[0082] In yet another embodiment the floor, wall and ceiling cladding is glued to a mirroring floor, wall and ceiling cladding to form a free-standing wall-section. Thus, a wall element is obtained exhibiting the following layer configuration: first top coating, support layer, adhesive fastening, adhesive fastening, support layer and first top coating. Such a wall element exhibits the functionality of the first top coatings on both outer surfaces. The wall element described above is suitable as an easy to install partitioning wall. Alternatively, the adhesive fastening can be dispensed with entirely. In that case, a support layer is equipped with a first top coating on both sides, i.e., on its first and second surface.

[0083] As far as applicable, all individual features shown in the individual embodiments can be combined and/or exchanged without leaving the scope of the invention.

LIST OF REFERENCE NUMERALS

[0084] 1 Floor, wall, and ceiling cladding [0085] 2 Support layer [0086] 20 First surface [0087] 22 Second surface [0088] 24 Polymer foam [0089] 26, 26′ Aluminium layer [0090] 27, 27′ Glass fibre layer [0091] 28 Carbon fibre layer [0092] 3 First top coating [0093] 30 Second top coating [0094] 4 Adhesive fastening [0095] 40 First adhesive layer [0096] 42 Backing [0097] 43 Backing [0098] 44 Second adhesive layer [0099] 46 Third adhesive layer [0100] 5 Tear-off film [0101] 6 Surface [0102] 60 Protrusion