FLOOR COVERING AND METHOD FOR THE PRODUCTION THEREOF

Abstract

The invention relates to a floor covering comprising a sheet material (11) having a polymer composition comprising a first polymeric component (K1) and a second polymeric component (K2), wherein the first polymeric component (K1) comprises at least one substance selected from a group consisting of a thermoplastic and a thermoplastic elastomer. The invention is characterized in that the second polymeric component (K2) comprises a rubber and in that the polymer composition is produced by mixing the first polymeric component (K1) and the second polymeric component (K2) after the first and second polymeric components (K1, K2) have been softened by supplying energy. The invention also relates to a method for producing the floor covering.

Claims

1. A floor covering comprising a sheet material having a polymer composition comprising a first polymeric component and a second polymeric component, wherein the first polymeric component comprises at least one substance selected from a group consisting of a thermoplastic and a thermoplastic elastomer, characterized in that the second polymeric component comprises a rubber and in that the polymer composition is produced by mixing the first polymeric component and the second polymeric component.

2. The floor covering according to claim 1, wherein the rubber of the second polymeric component contains at least one substance selected from the group consisting of styrene butadiene rubber, natural rubber, isoprene rubber, butadiene rubber, ethylene propylene rubber, ethylene propylene diene rubber, acrylate rubber, ethylene acrylate rubber, acrylonitrile butadiene rubber, hydrogenated acrylonitrile butadiene rubber, chloroprene rubber, chlorosulfonated polyethylene, ethylene vinyl acetate rubber, and silicone rubber.

3. The floor covering according to claim 1, wherein the second polymeric component comprises at least one polar rubber.

4. The floor covering according to claim 3, wherein the polar rubber comprises at least one monomer selected from the group consisting of acrylonitrile, vinyl acetate and methacrylate.

5. The floor covering according to claim 1, wherein the first polymeric component constitutes between 30 and 98 parts by weight relative to the total of the polymers in the polymer composition.

6. The floor covering according to claim 1, wherein the second polymeric component constitutes between 2 and 70 parts by weight relative to the total of the polymers in the polymer composition.

7. The floor covering according to claim 1 wherein in the polymer composition the first polymeric component and the second polymeric component are completely mixed with each other.

8. The floor covering according to claim 1, wherein the first polymeric component comprises at least one component A comprising an olefin-based polymer.

9. The floor covering according to claim 8, wherein component A comprises at least one olefin-based polymer selected from the group consisting of ethylene vinyl acetate, ethylene methacrylic acid, ethylene butyl acrylate, ethylene ethyl acrylate, very low density polyethylene, linear low density polyethylene, polyolefin elastomer, polyethylene, polypropylene, low density polyethylene and polyolefin plastomer.

10. The floor covering according to claim 1, wherein the first polymeric component comprises at least one component B comprising a polymer having acid groups and/or anhydride groups.

11. The floor covering according to claim 1, wherein the first polymeric component comprises at least one component C comprising a styrene-based thermoplastic elastomer.

12. The floor covering according to claim 11, wherein the styrene-based thermoplastic elastomer has a hard phase and a soft phase and in that the soft phase has a glass transition temperature TG of minus 50 C. or higher.

13. The floor covering according to claim 12, wherein the soft phase comprises styrene.

14. The floor covering according to claim 11, wherein component C comprises an isoprene monomer built in the polymer chain as 1,2-vinyl isomer.

15. The floor covering according to claim 11, wherein the styrene-based thermoplastic elastomer of component C comprises at least one compound selected from the group consisting of styrene-butadiene-styrene block copolymer, styrene-isoprene-styrene block copolymer, styrene-ethylene-butylene-styrene block copolymer and styrene-ethylene-propylene-styrene block copolymer.

16. A method for producing a floor covering comprising the following steps: providing a first polymeric component comprising at least one substance selected from a group consisting of a thermoplastic and a thermoplastic elastomer; providing a second polymeric component comprising a rubber; softening of the first polymeric component and the second polymeric component by supplying energy; producing a polymer composition by mixing the first polymeric component and the second polymeric component in the softened state in a mixer; forming the polymer composition into a sheet material.

Description

[0079] In the drawings:

[0080] FIG. 1: shows a schematic perspective view of a floor covering according to the invention;

[0081] FIG. 2: shows a schematic side view of a further embodiment of a floor covering according to the invention;

[0082] FIG. 3: shows a schematic side view of another embodiment of a floor covering according to the invention;

[0083] FIG. 4: shows a schematic representation of the production process.

[0084] FIG. 1 schematically shows a floor covering 1 according to the invention. The floor covering shown is a sheet material whose thickness d is considerably smaller than its length I and width b. In particular, the thickness d can be between 1 and 10 mm. The width b and the length l can be dimensioned according to the desired delivery form of the floor covering. In particular, the floor covering can be supplied in rolls or tiles.

[0085] The floor covering 1 has a base layer 2 with a polymer composition described in more detail below.

[0086] The base layer 2 has a usage face 3 and a rear face 4. The usage face 3 is arranged facing the room when the floor covering is used as intended. The usage face can be designed as a decorative side. The rear face 4 is arranged facing the substrate, for example the screed. The rear face 4 can be adhered to the subfloor using an adhesive for floor coverings, in particular a dispersion adhesive.

[0087] FIG. 2 shows a floor covering 1, which in turn comprises a base layer 2 of a polymer composition. The base layer 2 is provided with a covering layer 5 on its usage face 3. The covering layer 5 is a transparent film according to a preferred design. The covering layer 5 is permanently adhered to the base layer 2 via an adhesive layer 6. The covering layer 5 is resistant to the usual stresses of a floor covering. In particular, an ionomer film may form the covering layer 5. Such films may be made from DuPont's Surlyn 1706 material, for example. The adhesive layer may be made of DuPont's Nucrel 0903, for example. Nucrel 0903 comprises a copolymer of ethylene and methacrylic acid having an MA content of 9%. The covering layer 5 and the adhesive layer 6 can be provided in particular as coextruded material with a thickness of about 200 pm and laminated onto the previously produced base layer 2 by supplying heat.

[0088] The representation in the figures serves only to clarify the product structure. The representation is not true to scale.

[0089] The structure of the floor covering 1 shown in FIG. 3 corresponds to that shown in FIG. 2, as far as the base layer 2 and the usage face 3 are concerned. Reference is made to the corresponding description. In addition, floor covering 1 has a pre-applied adhesive layer 7 on the rear face 4. The adhesive layer 7 is provided with a removable cover 8. The floor covering 1 can be adhered to a substrate without the need for applying an adhesive when laying. For laying, it is sufficient to remove the cover 8 and bring the floor covering 1 that is equipped with the adhesive layer 7 into contact with the substrate.

[0090] FIG. 4 schematically shows the production of the floor covering. Initially, the first and second polymeric components K1 and K2 are provided. The first polymeric component K1 comprises a thermoplastic and/or a thermoplastic elastomer. The second polymeric component K2 comprises a rubber whose polymers are crosslinkable but substantially non-crosslinked. These may be the substances indicated in the embodiment below. For example, according to the fourth embodiment, 35 parts by weight of VLDPE and 35 parts by weight of EVA can be provided, which together form the first polymeric component K1. Furthermore, 30 parts by weight of EVM can be provided, which form the second polymeric component K2.

[0091] In addition, the other components of the polymer composition are provided. These are collectively referred to as K3. Other constituents may include in particular fillers, processing aids, oil, antioxidants and/or colorants. For example, 300 parts by weight of filler (FS), 0.5 parts by weight of processing aid (VHM) and 0.5 parts by weight of antioxidants (AS) can be provided according to the fourth embodiment. In addition, oil can be provided if the respective embodiment so provides. For example, 4.5 parts by weight of oil are provided for exemplary embodiment 10.

[0092] The first polymeric component K1 and the second polymeric component K2 as well as the other components K3 are placed together in a mixer 9 and mixed intensively. If, as indicated in the embodiments, the first or second polymeric component K1 and/or K2 comprises a plurality of substances, these are preferably added separately to the mixer 9, i.e. not yet mixed with each other. The mixer 9 can be designed e.g. as an internal mixer or as a mixing extruder. During mixing, shear forces can generate heat to soften the first and second polymeric components K1 and K2. The mixing process generates the shear forces in the material. Alternatively or additionally, heat can be supplied, e.g. by a heater. Preferably, the first and second polymeric components K1 and K2 are softened to such a degree that the polymers of the first and second components K1 and K2 are melted. The mixing process is carried out until the softened polymers of the first and second polymeric components K1 and K2 form a homogeneous mass. The result is a polymer blend. The particles of the filler are embedded in the polymer blend.

[0093] After mixing, the polymer composition is formed into a sheet material 10. Forming can be carried out, for example, by an extruder with a wide slot die head and/or by calendering in a calender line 11. Preferably, the polymer composition is first extruded by an extruder with a wide slot die head and then additionally calendered to the desired thickness.

[0094] Calendering takes place in particular in a warm state, in which the composition is already dimensionally stable but can still be plastically deformed. Subsequently, the sheet material 10 is cooled, e.g. to less than 60 C. Cooling can take place in particular via chill rolls.

[0095] The sheet material 10 can be sprinkled with decoration granules on the usage face 3 to create optically appealing floor coverings. The application of decoration granules can take place in particular before and/or during the forming process. The usage face 3 can also be decorated in another way.

[0096] If the floor covering 1 has a further layer, it can be applied to the sheet material 10. For example, a covering layer 5 with the adhesive layer 6 can be laminated onto the sheet material 10, which forms the base layer 2, in order to obtain the floor covering shown in FIG. 2. In addition, an adhesive layer 7 and a cover 8 can be applied to the rear face to obtain the floor covering shown in FIG. 3.

[0097] The rear face 4 can be sanded to achieve improved adhesive bonding. If the floor covering is provided with an adhesive layer 7, sanding is carried out before the adhesive layer 7 is applied.

[0098] In the following, a number of examples for the polymer composition are described. In addition, a peel strength is specified for each example. The peel strength is determined according to the standard EN 1372:2015. The adhesion is carried out onto beech plywood by means of the dispersion adhesive Wulff Suprastrong. The tensile strength and elongation at break are also indicated. These are determined in a test according to the standard ISO 37 on 51 test specimens at 23 C. In addition, the tables contain information on the tear strength determined in accordance with the standard ISO 34-1, method B, mode of operation A. The Shore D hardness is determined according to the standard DIN ISO 7619-1. The viscosity is determined as the melt volume flow rate (MVR) according to the standard DIN EN ISO 1133. The information refers in each case to the standards in the version valid on 1 Jul. 2016. The glass transition temperature TG is determined according to DIN EN ISO 11357-2 in the version valid on 1 Jul. 2016. The values stated each are determined according to the half-step height method.

[0099] The following components are components of the polymer composition given as an example:

First Polymeric Component K1

[0100] In the following, various substances are described that alone or together can form the first polymeric component in the embodiments. The substances can be classified into three groups called component A, component B and component C.

Component A

[0101] K1-VLDPE denotes a VLDPE. The product is available under the name Clearflex CL DO (Versalis). The density is 0.90 g/cm.sup.3. The melt volume flow rate MVR)(190) is 3 g/10 min.

[0102] K1-EVA denotes an EVA available under the product name GreenFlex ML 50 (Versalis). The proportion of vinyl acetate (VA) is 19%. The density is 0.94 g/cm.sup.3. The melt volume flow rate MVR)(190) is 2.5 g/10 min.

[0103] K1-POE denotes a POE that is available under the product name Exact 8210 (Exxon). The product contains an ethylene octene copolymer. The density is 0.882 g/cm.sup.3. The melt volume flow rate MVR (190) is 10 g/10 min.

Component B

[0104] K1-MAH-LDPE denotes a LDPE grafted with maleic acid anhydride (MAH). The product is available under the product name Fusabond E226 (DuPont). The LDPE is grafted with 1 wt % MAH. The density is 0.93 g/cm.sup.3. The melt volume flow rate MVR)(190) is 1.5 g/10 min.

Component C

[0105] K1-SIS denotes a thermoplastic elastomer comprising styrene isoprene styrene (SIS). The product is available under the product name Hybrar 5127 (Kuraray). SIS 1 contains isoprene monomers built in the polymer chain as 1,2-vinyl isomers. The proportion of isoprene groups in vinyl position is more than 70%. The glass transition temperature TG of the soft phase is plus 8 C. The density is 0.94 g/cm.sup.3. The melt volume flow rate MVR (190) is 5 g/10 min. The styrene content is 20%.

[0106] K1-SBS denotes an SBS. This is available under the product name Styroflex 2 G 66 (Styrolution). The styrene content is 60%. The glass transition temperature T.sub.G of the soft phase is minus 39 C. The density is 1.0 g/cm.sup.3. The melt volume flow rate MVR (200) is 13 g/10 min.

Second Polymeric Component K2

[0107] K2-NBR1 denotes an NBR available under the product name Krynac 3345 (Arlanxeo). The proportion of acrylonitrile is 33%. The density is 0.97 g/cm.sup.3. The Mooney viscosity (ML (1+4)/100 C.) is 45 MU. The solubility parameter is 19.0 MPa.sup.1/2.

[0108] K2-NBR2 denotes an NBR available under the product name Krynac 4975 (Arlanxeo). The proportion of acrylonitrile is 48.5%. The density is 1.0 g/cm.sup.3. The Mooney viscosity (ML (1+4)/100 C.) is 75 MU. The solubility parameter is 21.1 MPa.sup.1/2.

[0109] K2-EVM1 denotes an EVM available under the product name Levapren 500 (Arlanxeo). The proportion of vinyl acetate is 50%. The density is 1.0 g/cm.sup.3. The Mooney viscosity (ML (1+4)/100 C.) is 27 MU. The solubility parameter is 17.6 MPa.sup.1/2.

[0110] K2-EVM2 denotes an EVM available under the product name Levapren 800 (Arlanxeo). The proportion of vinyl acetate is 80%. The density is 1.11 g/cm.sup.3. The Mooney viscosity (ML (1+4)/100 C.) is 28 MU. The solubility parameter is 18.2 MPa.sup.1/2.

[0111] K2-EPDM denotes an EPDM that is available under the product name Keltan 2470 (Arlanxeo). The proportion of ethylene is 69%. The density is 0.86 g/cm.sup.3. The Mooney viscosity (ML (1+4)/100 C.) is 25 MU. The solubility parameter is 16.1 MPa.sup.1/2.

[0112] K2-NR denotes a natural rubber, which is available under the product name CV 60 (Weber & Schaer). The density is 0.93 g/cm.sup.3. The Mooney viscosity (ML (1+4)/100 C.) is 60 MU. The solubility parameter 8 is 16.5 MPa.sup.1/2.

[0113] K2-SBR denotes an SBR that is available under the product name Europrene 1502 (Versalis). The styrene content is 23.5%. The density is 0.94 g/cm.sup.3. The Mooney viscosity (ML (1+4)/100 C.) is 52 MU. The solubility parameter is 17.3 MPa.sup.1/2.

Further Components of the Polymer Composition

[0114] FS denotes a filler. In the recipe examples chalk is used as filler.

[0115] Oil denotes an oil. Synthetic oil is used in the recipe examples.

[0116] VHM denotes a processing aid. In the examples shown, stearic acid is used as a processing aid.

[0117] AS denotes an antioxidant. In the examples, Irganox 1010 (BASF) is used as an antioxidant.

[0118] The weight proportions for the individual components are given in the tables. The figures each refer to the total of the polymers in the polymer composition, which together make up 100 parts by weight.

[0119] Table 1 shows the compositions 1 to 7. Of these, composition 1 and 2 are comparative examples, while compositions 3 to 7 are exemplary embodiments of the invention. The polymer compositions each contain K1-VLDPE and K1-EVA as the first polymeric components. Compositions 1 and 2 do not contain rubber. Compositions 3 to 7 contain a rubber as a second polymeric component. Depending on the embodiment, these are K2-NBR, K2-EVM, K2-EPDM, K2-NR or K2-SBR. The embodiments 3 to 7 each contain 35 parts by weight of VLDPE and 35 parts by weight of K1-EVA. Thus, the first polymeric component formed from these makes up 70 parts by weight. The second polymeric component accounts for 30 parts by weight each. In addition, the embodiments shown in table 1 and in the other tables each contain filler (FS), processing aid (VHM) and antioxidant (AS). Composition 1, as well as the compositions described in the other tables, also contains synthetic oil (OIL).

[0120] The measured values shown in the lower part of the table show that the peel strength of compositions 1 and 2 is very low at 0.2 N/mm. The peel strength is a measure of the adhesion properties of the floor covering. For good adhesion of the floor covering to the subfloor, it is desirable that the peel strength is 0.5 N/mm or more. Examples 3 to 7 show that floor coverings made of compounds containing a rubber demonstrate considerably improved peel strength. Table 1 also clearly shows that compositions 3 to 7 also have improved mechanical properties compared to compositions 1 and 2. Thus, in particular the elongation at break is improved.

TABLE-US-00001 TABLE 1 1 2 3 4 5 6 7 K1VLDPE 50 50 35 35 35 35 35 K1EVA 50 50 35 35 35 35 35 K2NBR 30 K2EVM 30 K2EPDM 30 K2NR 30 K2SBR 30 FS 300 300 300 300 300 300 300 OIL 4.5 0 0 0 0 0 0 VHM 0.5 0.5 0.5 0.5 0.5 0.5 0.5 AS 0.5 0.5 0.5 0.5 0.5 0.5 0.5 Peel strength [N/mm] 0.2 0.2 1.0 2.3 0.5 0.6 0.7 Tensile strength [N/mm] 9.1 10.1 7.1 6.4 7.0 5.7 5.3 Elongation at break [%] 15 14 25 31 22 17 18 Tear strength [N/mm] 37 39 38 32 38 30 28 ISO Hardness [Shore D] 49 52 43 41 45 41 36 MVR [cm.sup.3/10 min] 8.4 4.8 <1 8.9 3.0 19.1 <1 190 C./21.6 kg

[0121] Table 2 shows further compositions 8 to 12. Of these, composition 8 is a comparative example, while compositions 9 to 12 are according to the invention. Compositions 8 to 12 each contain the first polymeric components K1-SIS, K1-EVA, K1-POE, K1-VLDPE and K1-MAH-LDPE in the weight proportions given in the table. As a second polymeric component, the compositions 9 to 12 contain K2-NBR1, K2-NBR2, K2-EVM1 or K2-EVM2, each with 20 parts by weight. In particular, the compositions 9 to 12 show that the peel strength is considerably improved. In addition to the non-crosslinked rubber, this is also because the composition for the first polymeric component contains component A, component B and component C. In addition, table 2 shows that very good mechanical values of the floor covering are obtained, such as tensile strength, elongation at break and tear strength. The values for elongation at break and tear strength are significantly higher than in the embodiments from table 1. The level achieved for the tensile strength with values, which are considerably higher than 5 N/mm throughout, is also well suitable for floor coverings.

TABLE-US-00002 TABLE 2 8 9 10 11 12 K1-SIS 40 35 35 35 35 K1-EVA 15 10 10 10 10 K1-POE 10 10 10 10 10 K1-VLDPE 15 10 10 10 10 K1-MAH-LDPE 20 15 15 15 15 K2-NBR 1 20 K2-NBR 2 20 K2-EVM 1 20 K2-EVM 2 20 FS 300 300 300 300 300 OIL 4.5 4.5 4.5 4.5 4.5 VHM 0.5 0.5 0.5 0.5 0.5 AS 0.5 0.5 0.5 0.5 0.5 Peel strength [N/mm] 0.9 2.1 1.8 3.4 3.3 Tensile strength [N/mm] 10.2 8.3 8.9 8.4 9.5 Elongation at break [%] 38 56 54 65 70 Tear strength [N/mm] 49 47 48 47 47 ISO Hardness [Shore D] 49 52 48 43 41 MVR [cm.sup.3/10 min] 7.2 6.3 9.5 8.6 8.4 190 C./21.6 kg

[0122] Table 3 shows compositions 13 to 19. Of these, 13 is a comparative example that does not contain rubber. Compositions 14 to 19 are exemplary embodiments. In each case, component 1 is a mixture of K1-SBS, K1-VLDPE, K1-POE, K1-EVA and K1-MAH-LDPE as well as K1-SIS. Thus, the compositions each contain the components A, B and C. The respective weight proportions are given in the table. Compositions 14 to 19 each contain K2-NBR1 in different proportions by weight as a second polymeric component. Table 3 clearly shows that particularly good adhesive values (peel strength) of the floor covering are achieved with compositions 14 to 19. Some of these are well above 1 N/mm. In addition, they initially increase with the increasing proportion of the second polymeric component (cf. compositions 14 to 17). A further increase in the weight proportion of K1-NBR1 does not lead to a further increase of the peel strength, although the good level is maintained. The table also shows that compositions 14 to 19 also have good mechanical properties in other respects. Thus, very good values for elongation at break are achieved. However, with an increasing proportion of K1-NBR 1, a certain decline in tear strength can be observed. Nevertheless, the values are predominantly above 25 N/mm and thus at a level well suitable for floor coverings.

[0123] The tables also show that the respective Shore hardness can be adjusted with the compositions. The values are consistently between Shore D 35 and 60 at a level suitable for floor coverings. A number of compounds achieve the particularly preferred Shore D hardness between 45 and 55.

TABLE-US-00003 TABLE 3 13 14 15 16 17 18 19 K1SBS 20 18 16 14 12 10 8 K1VLDPE 15 13.5 12 10.5 9 7.5 6 K1POE 10 9 8 7 6 5 4 K1EVA 15 13.5 12 10.5 9 7.5 6 K1MAH-LDPE 15 13.5 12 10.5 9 7.5 6 K1SIS 25 22.5 20 17.5 15 12.5 10 K2NBR 1 10 20 30 40 50 60 FS 300 300 300 300 300 300 300 OIL 4.5 4.5 4.5 4.5 4.5 4.5 4.5 VHM 0.5 0.5 0.5 0.5 0.5 0.5 0.5 AS 0.5 0.5 0.5 0.5 0.5 0.5 0.5 Peel strength [N/mm] 0.9 1.0 1.3 1.9 2.1 2.1 2.0 Tensile strength [N/mm] 10.1 9.7 8.6 7.4 6 4.8 3.5 Elongation at break [%] 58 83 74 53 59 56 91 Tear strength [N/mm] 47 45.7 40 35.1 29.7 26.6 22.8 ISO Hardness [Shore D] 52 51 48 45 39 34 28 MVR [cm.sup.3/10 min] 20.6 21.6 12.7 7.9 4.6 2.6 <1.0 190 C./21.6 kg