FLOORING MATERIAL

Abstract

The invention provides a ventilating synthetic floor-covering comprising a ventilating support layer and one or more synthetic layers wherein the ventilating support layer comprises a plurality of studs between which narrow ventilation channels are formed even when the floor-covering is compressed in normal use wherein the narrow ventilation channels have a width which is less than a principal dimension of the studs; a ventilating support layer; a production line for use in the preparation of a ventilating support layer wherein the ventilating support layer comprises a support layer and a plurality of studs wherein the production line comprises an embossing roller for embossing the plurality of studs on the support layer or a printing roller for printing the plurality of studs on the support layer wherein narrow ventilation channels are formed between the plurality of studs and wherein the narrow ventilation channels have a width which is less than a principal dimension of the studs; and a method of preparing a synthetic floor-covering according to the invention which method comprises a step of providing a synthetic floor-covering comprising an upper layer and a support layer; and one of the following steps: (a) embossing the support layer to form a plurality of studs between which one or more narrow ventilation channels are formed; (b) embossing the upper layer before embossing the support layer to form a plurality of studs between which one or more narrow ventilation channels are formed; (c) embossing the support layer to form a plurality of studs between which one or more narrow ventilation channels are formed before embossing the upper layer; (d) embossing the support layer and the upper layer at the same time wherein the support layer is embossed to form a plurality of studs between which one or more narrow ventilation channels are formed; or (e) applying one or more studs by printing to form a plurality of studs between which one or more narrow ventilation channels are formed;
wherein the narrow ventilation channels have a width which is less than a principal dimension of the studs.

Claims

1. A ventilating synthetic floor-covering comprising a ventilating support layer and one or more upper layers wherein the ventilating support layer is formed from a plastics material and wherein the ventilating support layer comprises a plurality of studs between which narrow ventilation channels are formed even when the floor-covering is compressed in normal use wherein the narrow ventilation channels have a width which is less than a principal dimension of the studs.

2. A floor-covering material as defined in claim 1 wherein the studs are formed from a foamed plastics material.

3. A floor-covering material as defined in claim 1 wherein the studs have substantially the same shape.

4. A floor-covering material as defined in claim 1 wherein the studs are resilient studs.

5. A floor-covering material as defined in claim 1 wherein the studs are tapering studs or perpendicular studs.

6. A floor-covering material as defined in claim 1 wherein the studs have a cross-sectional shape having three or four sides.

7. A floor-covering material as defined in claim 1 wherein a ratio of the principal dimension of the plurality of studs to a lesser dimension is from about 3:1 to about 1:1.

8. A floor-covering material as defined in claim 1 wherein the studs form a surface area which is sufficiently large in relation to the area covered by the narrow ventilation channels such that a floor-covering material may be adhered to a surface.

9. A floor-covering material as defined in claim 1 wherein the narrow ventilation channel has an upper channel width which is less than or substantially the same as its lower channel width.

10. A floor-covering material as defined in claim 1 wherein the studs of the support layer form a stud layer and wherein the narrow ventilation channels form less than 50% of the volume of the stud layer.

11. A floor-covering material as defined in claim 1 wherein the studs have a height which is sufficient for the plurality of studs to form compressed ventilation channels when the studs are compressed after use.

12. A floor-covering material as defined in claim 1 wherein the support layer comprises a support.

13. A floor-covering material as defined in claim 1 wherein the upper layer includes one or more of the following layers: a foamed layer, a printing layer and a printed design layer, a decorative layer, a clear wear layer, a non-slip layer, and/or an external protective coating layer.

14. A floor-covering material as defined in claim 1 wherein the plurality of studs have a square and/or rectangular shape.

15. A floor-covering material as defined in claim 1 wherein a ratio of the principal dimension of the studs to a lesser dimension is from about 2:1 to about 1:1.

16. A ventilating support layer comprising a plurality of studs between which narrow ventilation channels are formed even when the floor-covering is compressed in normal use wherein the narrow ventilation channels have a width which is less than a principal dimension of the studs.

17. A method of preparing a synthetic floor-covering as defined in claim 1 which method comprises a step of providing a synthetic floor-covering comprising an upper layer and a support layer; and one of the following steps: (a) embossing the support layer to form a plurality of studs between which one or more narrow ventilation channels are formed; (b) embossing the upper layer before embossing the support layer to form a plurality of studs between which one or more narrow ventilation channels are formed; (c) embossing the support layer to form a plurality of studs between which one or more narrow ventilation channels are formed before embossing the upper layer; (d) embossing the support layer and the upper layer at the same time wherein the support layer is embossed to form a plurality of studs between which one or more narrow ventilation channels are formed; or (e) applying one or more studs by printing to form a plurality of studs between which one or more narrow ventilation channels are formed; wherein the narrow ventilation channels have a width which is less than a principal dimension of the studs.

18. A method as defined in claim 17 wherein the support layer is foamed.

19. A method as defined in claim 17 wherein the upper layer is one or more of the following layers: a foamed layer, a printing layer and a printed design layer, a decorative layer, a clear wear layer, and/or an external protective coating layer.

Description

[0060] The invention will now be described with reference to the following Figures of the accompanying drawings which are not intended to limit the scope of the invention in which:

[0061] FIG. 1 shows a schematic plan view of a known support layer;

[0062] FIG. 2 shows a schematic cross-section of a compressed known support layer;

[0063] FIG. 3 shows a schematic plan view of a ventilating support layer for use in a floor-covering material according to the invention;

[0064] FIG. 4 shows a schematic plan view of a compressed ventilating support layer for use in a floor-covering material according to the invention;

[0065] FIG. 5 shows a detailed schematic cross-section of a part of a ventilating support layer for use in a floor-covering material according to the invention showing dimensions of the studs and the stud ventilation gaps;

[0066] FIG. 6 shows a schematic plan view of a ventilating support layer for use in a floor-covering material according to the invention showing dimensions of the studs and the stud ventilation gaps;

[0067] FIG. 7 shows a schematic cross-section of a first embodiment of a floor-covering material according to the invention which incorporates the ventilating support layer shown in FIGS. 3 to 6;

[0068] FIG. 8 shows a schematic cross-section of a second embodiment of a floor-covering material according to the invention which incorporates the ventilating support layer shown in FIGS. 3 to 6;

[0069] FIG. 9 shows a schematic cross-section of a third embodiment of a floor-covering material according to the invention which incorporates the ventilating support layer shown in FIGS. 3 to 6;

[0070] FIG. 10 shows a schematic cross-section of a first embodiment of a production line for use in a first embodiment of an embossing step for use in the method of preparing a synthetic floor-covering according to the invention wherein the embossing step forms the ventilating support layer shown in FIGS. 3 to 6;

[0071] FIG. 11 shows a schematic cross-section of a second embodiment of a production line for use in a second embodiment of an embossing step for use in the method of preparing a synthetic floor-covering according to the invention wherein the embossing step forms the ventilating support layer shown in FIGS. 3 to 6;

[0072] FIG. 12 shows a schematic cross-section of a third embodiment of a production line for use in a third embodiment of an embossing step for use in the method of preparing a synthetic floor-covering according to the invention wherein the embossing step forms the ventilating support layer shown in FIGS. 3 to 6;

[0073] FIG. 13 shows a schematic cross-section of a first embodiment of a printing production line for use in a first embodiment of a step of applying the plurality of studs by printing for use in the method of preparing a synthetic floor-covering according to the invention wherein the printing step forms the ventilating support layer shown in FIGS. 3 to 6; and

[0074] FIG. 14 shows a schematic cross-section of a second embodiment of a printing production line for use in a second embodiment of a step of applying the plurality of studs by printing for use in the method of preparing a synthetic floor-covering according to the invention wherein the printing step forms the ventilating support layer shown in FIGS. 3 to 6.

[0075] A ventilating support layer for use in a floor-covering material according to the invention is indicated generally at 20 on FIGS. 3 to 6. Ventilating support layer 20 comprises a stud layer 21 formed by a plurality of studs 22 and a support layer 24. The stud layer 21 provides a texture on a lower surface of the support layer 24 such that the studs 22 engage a sub-floor surface 16 to which a floor-covering material 30,130,230 is applied. The stud layer 21 may be an embossed texture or a printed texture, depending on how it is applied.

[0076] The studs 22 which form the stud layer 21 are formed from foamed plastics material. The foamed plastics material may be mechanically foamed by incorporating one or more types of compressible plastic spheres or may be chemically foamed by being formed with a foaming agent such as an azodicarbonamide.

[0077] Each stud 22 in stud layer 21 has an inverted truncated rectangular pyramidal shape which extends downwardly from support layer 24 to form a substantially flat floor-engaging surface 26 which has a principal dimension x and a lesser dimension y as indicated on FIG. 6. The ratio of principal dimension x (which is the length of a stud 22) to lesser dimension y (which is the width of a stud 22) may be from about 2:1 to 1:1. Alternatively, where the stud 22 has an inverted truncated square pyramidal shape, the principal dimensions are x and y. The principal dimension x of the stud floor-engaging surface 26 may be from 1 to 10 mm; the lesser dimension y of the stud floor-engaging surface 26 may be the same as the principal dimension x or less than it.

[0078] The studs 22 are separated by a narrow ventilation channel 23 which as shown on FIG. 5. Narrow ventilation channel 23 is defined by an upper channel width w2 which is the closest distance between the tops of adjacent studs 22 (typically measured at an angle of 90 between proximal sides of studs 22) at the level of support layer 24 and a lower channel width w1 which is the closest distance between the bottoms of adjacent studs 22 at the level of the floor-engaging surface 26. As the studs 22 have an inverted truncated rectangular pyramidal shape, upper channel width w2 is less than lower channel width w1 as the studs 22 are tapering studs 22 having a truncated pyramidal shape which taper from the support layer 24 to the floor-engaging surface 26. The upper channel width w2 may be from 0 to 2 mm. The lower channel width w1 may be from 0.1 to 2 mm.

[0079] In an alternative embodiment, the studs 22 may have a truncated pyramidal shape having a cross-sectional shape such the studs may be arranged to have narrow ventilation channels 23,25 between them such as a triangular cross-sectional shape.

[0080] Each stud 22 has a height h indicated on FIG. 5 which is measured from support layer 24 to floor-engaging surface 26. Height h may be from 0.05 mm to 1 mm. As shown in FIG. 4 after heavy use of the floor-covering material 30,130,230 incorporating a ventilating support layer 20 on a sub-floor 16, the studs are compressed to form compressed studs 22A which have a height which is still sufficient for a compressed narrow ventilating channel 23A to be formed. Compressed stud layer 21A still spaces support layer 24 from the surface to which the floor-covering material 30,130,230 has been applied.

[0081] In an alternative embodiment, the studs 22 may be perpendicular studs 22 which have a right prismatic shape and do not taper such that upper channel width w1 is substantially the same as lower channel width w2.

[0082] The support layer 24 comprises a support which is a layer of fabric (such as a scrim layer) impregnated with a gelled plastic material. The support may include glass-fibre, vinylon fibre, high-density polyethylene fibre, aramid fibre, carbon fibre, cellulose, and/or polyester fibre; for example, a cellulose/polyester support reinforced with a 32 tex glass crennette. The gelled plastic material may comprise one or more of the following polymers: PVC, polyvinyl butyral (PVB), polylactic acid (PLA), polyester and/or polyacrylate.

[0083] The first embodiment of a floor-covering material according to the invention is indicated generally at 30 on FIG. 4. Floor-covering material 30 comprises a ventilating support layer 20 which is formed from a stud layer 21 and a support layer 24. Floor-covering material 30 further comprises a lower layer 32 in the form of a pigmented printing layer on an upper surface of the support layer 24, a printed decorative layer 34 on an upper surface of the pigmented printing layer 32, and a clear wear layer 36 on an upper surface of the decorative layer 34. The support layer 24 may comprise one or more of the following polymers: PVC, polyvinyl butyral (PVB), polylactic acid (PLA), polyester and/or polyacrylate.

[0084] The second embodiment of a floor-covering material according to the invention is indicated generally at 130 on FIG. 5. Like features of the second embodiment to the first embodiment of the floor-covering material are identified by like reference numerals. Floor-covering material 130 comprises the layers of a floor-covering material 30 according to the first embodiment which are the ventilating support layer 20, the lower layer 32 in the form of a pigmented printing layer, a printed decorative layer 34, and a wear layer 36. In addition, the floor covering material 130 additionally comprises a protective coating layer 38 applied to an upper surface of the wear layer 36. The protective coating layer 38 comprises a cured polymer layer. Suitable polymers for use in the protective coating layer 38 include polyurethane, polyacrylate, urethane acrylate or a PVDF based composition. A suitable coating composition for forming protective coating layer 38 is a UV curable mixture containing from 20 to 30 parts by weight of oxybis(methyl-2,1-ethanediyl) diacrylate, from 10 to less than 20 parts by weight of 2-phenoxyethyl acrylate, from 10 to less than 20 parts by weight of acrylate resin, from 2.5 to 5 parts by weight of (1-methyl-1,2-ethanediyl)bis[oxy(methyl-2,1-ethanediyl)] diacrylate, from 1 to 5 parts by weight of benzophenone and from 1 to 5 parts by weight of 1-6,hexanedioldiacrylate was prepared.

[0085] The third embodiment of a floor-covering material according to the invention is indicated generally at 230 on FIG. 6. Like features of the third embodiment to the first embodiment of the floor-covering material are identified by like reference numerals. Floor-covering material 230 comprises the layers of a floor-covering material 130 according to the second embodiment which are the pre-coated fabric layer 20, the lower layer 32 which is a pigmented printing layer, a printed decorative layer 34, a wear layer 36, and a protective coating layer 38. In addition, the floor-covering material 230 comprises a non-slip layer 40 applied to an upper surface of the protective coating layer 38. Non-slip layer 40 comprises one or more particles 42 suitable for providing a non-slip surface wherein such particles 42 are at least partially embedded in the wear layer 36. The particles 38 may comprise one or more types of slip resistant particles such as aluminium oxide, silicon carbide, quartz and/or glass. The floor-covering material 230 is suitable for use as a covering material for a floor as the non-slip surface is intended to reduce the risk of a person slipping when walking on the floor-covering material.

[0086] In an alternative embodiment, the non-slip layer 40 may be applied to the wear layer 36 before the protective coating layer 38 is applied such that the particles 42 are at least partially embedded in the wear layer 36. In an alternative embodiment, the lower layer 32 may be replaced by a decorative layer without applying a printed decorative layer 34 where a printed design is not needed. In an alternative embodiment, the lower layer 32 may be replaced by a plastic layer or foamed plastic layer and a decorative layer or a pigmented printing layer and a printed decorative layer 34 may be applied on top of the lower layer 32.

[0087] The floor-covering material 30,130,230 may optionally be embossed. The floor-covering material 30,130,230 may optionally be cut up into tiles.

[0088] A first embodiment of a partial production line for use in the method of the invention to form an embossed texture is indicated generally at 50 on FIG. 10. Embossing production line 50 comprises three pairs of opposed rollers which process a floor covering web 60 which is propelled to run between each pair of rollers. Floor covering web 60 has a floor covering upper layer 62 and a floor covering support layer 24. The first pair of rollers form a stud embossing station and are a lower roller which is a stud embossing roller 54 and an upper pressure roller 56. The second pair of rollers form a cooling station and are an upper cooling roller 58 and lower cooling roller 58. The third pair of rollers form an upper layer embossing station and are an upper roller which is upper layer embossing roller 52 and a lower roller which is pressure roller 56.

[0089] In operation, embossing production line 50 embosses a texture of the plurality of studs 22 (which form the stud layer 21) on floor covering support layer 24 by the application of heat and pressure by upper pressure roller 56 against the floor covering web 60 onto the stud embossing roller 54. The floor covering web 60 is then cooled by the cooling rollers 58 before an emboss texture is applied to the floor covering upper layer 62 by upper layer embossing roller 52 and pressure roller 56.

[0090] A second embodiment of a partial production line for use in the method of the invention to form an embossed texture is indicated generally at 150 on FIG. 11. Like features to the first embodiment of the partial production line are identified by like reference numerals. Embossing production line 150 comprises three pairs of opposed rollers which process a floor covering web 60 which is propelled to run between each pair of rollers. Floor covering web 60 has a floor covering upper layer 62 and a floor covering support layer 24. The first pair of rollers form an upper layer embossing station and is an upper roller which is upper layer embossing roller 52 and a lower roller which is pressure roller 56. The second pair of rollers form a cooling station and is an upper cooling roller 58 and lower cooling roller 58. The third pair of rollers form a stud embossing station and are a lower roller which is a stud embossing roller 54 and an upper pressure roller 56.

[0091] In operation, embossing production line 150 first applies an emboss texture to the floor covering upper layer 62 using heat and pressure by upper layer embossing roller 52 and pressure roller 56. The floor covering web 60 is then cooled by the cooling rollers 58. A texture of the plurality of studs 22 (which form the stud layer 21) is then embossed on floor covering support layer 24 by the application of heat and pressure by upper pressure roller 56 against the floor covering web 60 onto the stud embossing roller 54.

[0092] A third embodiment of a partial production line for use in the method of the invention to form an embossed texture is indicated generally at 250 on FIG. 12. Like features to the first and second embodiments of the partial production line are identified by like reference numerals. Embossing production line 250 comprises two pairs of opposed rollers which process a floor covering web 60 which is propelled to run between each pair of rollers. Floor covering web 60 has a floor covering upper layer 62 and a floor covering support layer 24. The first pair of rollers form a dual emboss station and is an upper roller which is upper layer embossing roller 52 and a lower roller which is a stud embossing roller 54. The second pair of rollers form a cooling station and is an upper cooling roller 58 and lower cooling roller 58.

[0093] In operation, embossing production line 150 applies emboss textures to the floor covering upper layer 62 and to the floor covering support layer 24 to form a texture of the plurality of studs 22 (which form the stud layer 21) using heat and pressure by upper layer embossing roller 52 and pressure roller 56. The floor covering web 60 is then cooled by the cooling rollers 58.

[0094] In an alternative embodiment, the cooling rollers 58 may be omitted.

[0095] A first embodiment of a partial production line for use in the method of the invention to apply a printed texture is indicated generally at 70 on FIG. 13. Printing production line 70 comprises two pairs of opposed rollers which process a floor covering web 60 which is propelled to run between each pair of rollers. Floor covering web 60 has a floor covering upper layer 62 and a floor covering support layer 24. The first pair of rollers forms an upper layer embossing station which comprises an upper roller which is upper layer embossing roller 52 and a lower roller which is pressure roller 56. The second pair of rollers forms a screen-printing station which comprises an upper roller which is pressure roller 56 and a lower roller which is a screen-printing roller 72.

[0096] Screen-printing roller 72 forms screen-printing apertures 74 which are arranged to be of a suitable size, shape, and orientation to apply a printed texture of the plurality of studs 22. Screen-printing roller 72 has a roller annulus 76 arranged within roller 72. Roller annulus 76 forms an internal source of plastic material for the screen-printing apertures 74. Suitable plastic material for use in rotary screen printing includes PVC plastisol, polyurethane, or silicone.

[0097] In operation, printing production line 70 applies an emboss texture to the floor covering upper layer 62 by upper layer embossing roller 52 and pressure roller 56. The floor covering web 60 is then optionally cooled by the cooling rollers (not shown). A screen-printing step is then performed by applying a printed texture of the plurality of studs 22 (which form the stud layer 21) on floor covering support layer 24 by screen-printing plastic material from apertures 74. In an alternative embodiment, the emboss texture may be applied to the floor covering upper layer 62 after the screen-printing step (for example, subsequently in the method of manufacture).

[0098] A second embodiment of a partial production line for use in the method of the invention to apply a printed texture is indicated generally at 170 on FIG. 14. Like features to the first embodiment of the printing production line 70 are identified by like reference numerals. Printing production line 170 comprises a plastic material trough 86 and two pairs of opposed rollers which process a floor covering web 60 which is propelled to run between each pair of rollers. Floor covering web 60 has a floor covering upper layer 62 and a floor covering support layer 24. The first pair of rollers form an upper layer embossing station which comprises an upper roller which is upper layer embossing roller 52 and a lower roller which is pressure roller 56. The second pair of rollers form a rotogravure printing station which comprises an upper roller which is pressure roller 56 and a lower roller which is a rotogravure roller 82.

[0099] Trough 86 provides plastic material for forming the studs 22. Trough 86 includes a doctor blade 88. Rotogravure roller 82 forms rotogravure cavities 84 for receiving plastic material from trough 86. Rotogravure cavities 84 are arranged to be of a suitable size, shape, and orientation to apply a printed texture of the plurality of studs 22. Rotogravure roller 82 is arranged in relation to the trough 86 such that on rotation of roller 82, plastic material from the trough 86 fills the rotogravure cavities 84. The doctor blade 88 is arranged to seal the trough 86 and to clean the surface of the rotogravure roller 82 of any excess plastics material.

[0100] In operation, printing production line 70 applies an emboss texture to the floor covering upper layer 62 by upper layer embossing roller 52 and pressure roller 56. The floor covering web 60 is then optionally cooled by the cooling rollers (not shown). A printed texture of the plurality of studs 22 (which form the stud layer 21) is then applied on floor covering support layer 24 by printing plastic material from rotogravure cavities 84. In an alternative embodiment, the emboss texture may be applied to the floor covering upper layer 62 after the rotogravure printing step (for example, subsequently in the method of manufacture).