Multilayer Structure for Producing Floor Covering

Abstract

A multilayer structure for the production of a floor covering of a transport vehicle successively includes an upper wear layer of plastic material, a first adhesive layer, a woven reinforcement, a second adhesive layer, a non-woven textile layer comprising self-extinguishing fibers, said layers being bonded together to form the multilayer structure.

Claims

1. A multilayer structure for the production of a floor covering of a transport vehicle, said multilayer structure successively comprising an upper wear layer of plastic material, a first adhesive layer, a woven reinforcement, a second adhesive layer, a non-woven textile layer comprising self-extinguishing fibers, said layers being bonded together to form the multilayer structure.

2. The multilayer structure according to claim 1, wherein the non-woven textile layer has an oxygen limiting index of more than 0.28 in accordance with NF EN ISO 4589-2/A1 standards.

3. The multilayer structure according to claim 2, wherein the non-woven textile layer has an oxygen limiting index of more than 0.32 in accordance with NF EN ISO 4589-2/A1 standards.

4. The multilayer structure according to claim 1, wherein the non-woven textile layer comprises fibers chosen from among fibers of polyetherimide, polyester, polyacrylate, aramide, para-aramide, oxidized polyacrylonitrile, aromatic polyamide and mixtures thereof.

5. The multilayer structure according to claim 4, wherein the non-woven textile layer is produced from a mixture of polyester fibers and polyetherimide fibers, a mixture of polyester fibers and aramide fibers, a mixture of polyacrylate fibers and aramide fibers, a mixture of polyester fibers and aramide fibers, or a mixture of oxidized polyacrylonytrile fibers and para-aramide fibers.

6. The multilayer structure according to claim 1, wherein the woven reinforcement is produced from glass fibers, polyamide fibers or polyester fibers.

7. The multilayer structure according to claim 1, further comprising a layer of printed decorative film disposed between the upper wear layer and the first adhesive layer.

8. The multilayer structure according to claim 7, further comprising an intermediate layer of plastic material, disposed between the layer of printed decorative film and the first adhesive layer.

9. The multilayer structure according to claim 1, wherein the woven reinforcement is impregnated with a thermoplastic or thermosetting polymer.

10. The multilayer structure according to claim 9, wherein the woven reinforcement is impregnated with a mixture comprising a plastic material and carbon black.

Description

BRIEF DESCRIPTION OF THE FIGURES

[0028] Further advantages and features will become more apparent from the following description of the multilayer structure, given by way of a non-limiting example and based on the attached drawings, in which:

[0029] FIG. 1 is a schematic view in cross-section of a first embodiment of the multilayer structure;

[0030] FIG. 2 is a schematic view similar to that of FIG. 1, illustrating a second embodiment of the multilayer structure;

[0031] FIG. 3 is a schematic view similar to that of FIG. 1, illustrating a third embodiment of the multilayer structure;

[0032] FIG. 4 is a schematic view similar to that of FIG. 1, illustrating a fourth embodiment of the multilayer structure.

DETAILED DESCRIPTION

[0033] The present disclosure concerns a multilayer structure (1) for the production of a floor covering, particularly for passenger transport vehicles, for example in the aeronautics industry. The multilayer structure (1) has good fire-resistant properties, better durability than carpeting and better properties for cleaning, dimensional stability and limitation of telegraphing.

[0034] The multilayer structure (1) can be in any form, particularly as a panel, tile, and preferably in roll form.

[0035] With reference to FIGS. 1 to 4, the multilayer structure (1) successively comprises an upper wear layer (2) of plastic material, a first adhesive layer (3), a woven reinforcement (4), a second adhesive layer (5), a non-woven textile layer (6) comprising self-extinguishing fibers, said layers being bonded together to form the multilayer structure (1). The main functions of the upper wear layer (2) of plastic material are control of slipperiness, resistance to wear and ease of cleaning. The upper wear layer can possibly be embossed or varnished on the surface.

[0036] The upper wear layer (2) can consist of a calendered or extruded layer, or even pressed. It can in particular be obtained from plasticized PVC. In general, and in a manner well known to the person skilled in the art, a wear layer may be obtained from a composition comprising a polymer, for example PVC or polyurethane, a plasticizer and possibly fillers, stabilizers, lubricants, additives and pigments. The upper wear layer can consist of one or more layers.

[0037] The woven reinforcement (4) can, with difficulty, be bonded with a layer of plastic material or a non-woven textile layer (6) using conventional hot-lamination techniques. If the upper wear layer (2) is hot-laminated onto the woven reinforcement (4), adherence is poor and easily delaminates. Thus, the upper wear layer (2) is not directly bonded to the woven reinforcement (4) without an intermediate layer. As a result, the first and second adhesive layers (3, 5) make it possible to bond the upper wear layer (2) to the woven reinforcement (4) and the woven reinforcement to the non-woven textile layer without risk of delamination. The first and/or the second adhesive layer can be achieved with polyurethane glue. Alternatively, the first and/or the second adhesive layer may consist of a hot melt film such as a co-polyamide film or thermoplastic polyurethane (TPU) or a copolyester film (coPes).

[0038] The woven reinforcement (4) improves the rigidity and dimensional stability of the multilayer structure. The woven reinforcement (4) is preferably woven according to a plain weave, although a twill weave or satin weave can be used. The weave (4) is preferably produced from glass fibers, polyamide fibers or polyester fibers. In particular, the glass fibers can have a linear density of between 22 Tex and 68 Tex. The polyester fibers can have a linear density on the order of 1100 decitex. In particular, the polyamide fibers can have a linear density of between 44 decitex and 78 decitex.

[0039] The woven reinforcement (4) generally has a thickness of between 150 m and 300 m, preferably between 215 m and 225 m. The woven reinforcement (4) generally has a surface weight of between 150 and 300 g/m.sup.2, although this value depends on the type of fibers used.

[0040] Advantageously, the woven reinforcement (4), particularly when it is produced from glass fibers, has between 17 and 18 warp yarns per centimeter, and between 13.5 and 14 weft yarns per centimeter. Below 17 warp yarns per centimeter or 13.5 weft yarns per centimeter, the woven reinforcement (4) obtained is too porous, particularly with a linear density between 22 and 68 Tex. Above 18 warp yarns per centimeter or 14 weft yarns per centimeter, the woven reinforcement is difficult to produce with conventional production tools, particularly with a linear density of between 22 and 68 Tex.

[0041] The non-woven textile layer (6) comprises self-extinguishing fibers so as to improve the fire resistance of the multilayer structure while improving the walking comfort of the floor covering. The non-woven textile layer can in particular comprise fibers chosen from among fibers of polyetherimide, polyester, polyacrylate, aramide, para-aramide, oxidized polyacrylonitrile, aromatic polyamide and mixtures thereof. The quantity of each type of fiber can easily be adapted by the person skilled in the art to achieve an oxygen limiting index value greater than 0.21, than 0.28 or than 0.32 in compliance with NF EN ISO 4589-2/A1 standards, particularly from oxygen limiting index values of each type of fiber used in producing the non-woven textile layer and in accordance with the desired applications.

[0042] In order to improve the comfort of the floor covering while preserving good fire-resistant properties and limiting manufacturing costs, the non-woven textile layer (6) can be produced from a mixture of polyester fibers and polyetherimide fibers, a mixture of polyester fibers and aramide fibers, a mixture of polyacrylate fibers and aramide fibers, a mixture of polyester fibers and aramide fibers, or a mixture of oxidized polyacrylonytrile fibers and para-aramide fibers.

[0043] The non-woven textile layer (6) can be produced by any known means, particularly by dry process, melt bonding, wet-laid process or by formation in situ. Known techniques for consolidating the non-woven textile layer (6) can also be employed, particularly chemical or hydraulic consolidation. Preferably, the non-woven textile layer (6) is produced by a dry process comprising a consolidation step using needle punching that binds the fibers together.

[0044] Preferably, the fibers of the non-woven textile layer (6) are not partially or even totally impregnated with a thermoplastic and/or heat-setting resin in order to not limit their displacement in the non-woven textile layer (6) and to preserve good flexibility properties.

[0045] The non-woven textile layer (6) generally has a thickness of between 0.5 mm and 1 cm, preferably between 3 mm and 5 mm. A thickness of less than 3 mm generally reduces the walking comfort of the multilayer structure. A thickness of more than 5 mm significantly degrades the resistance to puncturing of the multilayer structure. A thickness of the non-woven textile layer (6) of between 3 mm and 5 mm offers a good compromise between comfort and resistance to puncturing.

[0046] The non-woven textile layer (6) advantageously has a surface weight of between 50 g/m.sup.2 and 1000 g/m.sup.2, preferably between 250 g/m.sup.2 and 450 g/m.sup.2. A surface weight of more than 450 g/m.sup.2 can reduce the resistance to puncturing of the multilayer structure (1). However, a surface weight of less than 250 g/m.sup.2 can improve resistance to puncturing but it decreases walking comfort. A surface weight of between 250 g/m.sup.2 and 450 g/m.sup.2 offers a good compromise between comfort and resistance to puncturing.

[0047] According to a first embodiment illustrated in FIG. 1, the multilayer structure (1) successively comprises an upper wear layer (2) of plastic material, a first adhesive layer (3), a woven reinforcement (4), a second adhesive layer (5), a non-woven textile layer (6) comprising self-extinguishing fibers, said layers being bonded together to form the multilayer structure (1). The upper wear layer of plastic material (2) is bonded to the woven reinforcement (4) by means of the first adhesive layer (3). The woven reinforcement (4) is bonded to the non-woven textile layer (6) by means of a second adhesive layer (5).

[0048] According to a second embodiment illustrated in FIG. 2, the multilayer structure (1) successively comprises a transparent upper wear layer (2) of plastic material, a printed decorative film (7) disposed between the upper wear layer (2) and the first adhesive layer (3) and, visible through the upper layer (2), a first adhesive layer (3), a woven reinforcement (4), a second adhesive layer (5) and a non-woven textile layer comprising self-extinguishing fibers, said layers being bonded together to form the multilayer structure (1).

[0049] The printed decorative film (7) is printed directly by any known techniques such as rotogravure or digital printing techniques. A wide variety of decorations can thereby be offered. The printed film can in particular be a polymer film produced from polyvinyl chloride (PVC), polyethylene terephthalate glycol (PETG) or poly(ethylene terephthalate) (PET), with a thickness generally between 0.2 and 0.5 mm. The printed decorative film (7) and the upper wear layer (2) are bonded by any known means such as hot lamination.

[0050] In this embodiment the printed decorative film (7) cannot be hot laminated onto the woven reinforcement (4) in order to bond them together. The first adhesive layer (3) does make it possible to bond the printed decorative film (7) to the woven reinforcement (4) without risk of delamination.

[0051] According to a third embodiment illustrated in FIG. 3, the multilayer structure (1) successively comprises a transparent upper wear layer of plastic material (2), a printed decorative film (7) visible through the upper layer (2), an intermediate layer of plastic material (8) disposed between the printed decorative film layer (7) and a first adhesive layer (3), a woven reinforcement (4), a second adhesive layer (5) and a non-woven textile layer comprising self-extinguishing fibers.

[0052] The intermediate layer of plastic material (8) makes it possible to reduce the toxicity of fumes generated by the combustion of the surface layer and/or the printed polymer film, particularly when they are produced from polymers that are not self-extinguishing. For example, it is possible to produce a multilayer structure comprising an upper wear layer of thermoplastic polyurethane (TPU) and/or a printed polymer film of polyethylene terephthalate glycol (PETG) in association with an intermediate layer produced from polyvinyl chloride (PVC). The presence of the intermediate layer produced from PVC makes it possible to limit the propagation of flames and the appearance of toxic fumes during combustion of the multilayer structure. In particular, this embodiment makes it possible to obtain a floor covering that complies with ABD0031 standards. The thickness of the intermediate layer is generally between 0.2 mm and 0.5 mm.

[0053] In this embodiment, the intermediate layer of plastic material (8) cannot be hot laminated onto the woven reinforcement (4) in order to bond them together. The first adhesive layer (3) enables the intermediate layer of plastic material (8) to be bonded to the woven reinforcement (4) without risk of delamination.

[0054] According to a fourth embodiment illustrated in FIG. 4, the multilayer structure (1) successively comprises a transparent upper wear layer (2) of plastic material, a first adhesive layer (3), a woven reinforcement (4), a second adhesive layer (5), a second woven reinforcement impregnated with a heat setting polymer (9), a third adhesive layer (10) and a non-woven textile layer comprising self-extinguishing fibers (6). The second woven reinforcement impregnated with a thermosetting polymer (9) contributes greater rigidity to the structure (1) and makes it possible to limit the telegraphing phenomena. In particular, the thermosetting polymer can be a phenolic resin. The third adhesive layer (10) can be produced from polyurethane glue or can consist of a hot melt film or double face film, i.e. a polymer film having an adhesive on both faces thereof.

Example 1

[0055] A multilayer structure (1) is produced as described in FIG. 2.

[0056] Said multilayer structure (1) successively comprises: [0057] A transparent upper wear layer (2) of calendered PVC 0.45 mm thick [0058] A printed decorative film (7) of PVC 0.3 mm thick. The decorative film is printed by digital printing then complexed onto the upper wear layer by a hot lamination process. [0059] A first polyurethane glue layer (3) 35 g/m.sup.2 [0060] A woven reinforcement (4) of glass fibers of 68 Tex. The reinforcement has a plain weave, a surface weight of 219 g/m.sup.2, a thickness of 0.2 mm, 17.4 warp yarns per centimeters and 13.8 weft yarns per centimeter [0061] A second polyurethane glue layer (5) 90 g/m.sup.2 [0062] A non-woven textile layer (6) of 300 g/m.sup.2 and 3 mm thick. The non-woven textile layer is produced from a mixture of polyetherimide and polyester fibers. Said non-woven textile layer is marketed by the National Non-woven Company under the commercial name KushnBlok Composite Cushioning Felt (CCF).

[0063] The multilayer structure thus formed can be used as floor covering in the aeronautics industry in roll form.

[0064] Different tests are performed on the floor covering thus obtained. The results of these tests are given in Table 1.

TABLE-US-00001 TABLE 1 Test Standard Value Abrasion resistance ISO9352 (2012) 143 3 mg Resistance to indentation - NF EN ISO 24343- 0.4 mm puncture 1 (April 2012) Fire resistance Duration of combustion FAR 25.853 4 1 s Burned length 80 10 mm Duration of combustion of drops 0 s Slipperiness FAR 25.793 Dynamic friction coefficient on MIL-W-5044C 0.55 0.01 dry leather Weight ISO 2286 (2016) 1533 12 g/m.sup.2 Thickness ISO 2286 (2016) 4.52 0.08 mm Dimensional stability L ISO 23999 (2012) 0.10 0.03% Dimensional stability T ISO 23999 (2012) 0.10 0.04%

[0065] The results of these tests show that the floor covering is sufficiently durable to satisfy the tests of resistance to abrasion and to puncturing according to ISO 9352 (2012) and the NF EN ISO 24343-1 (April 2012). Furthermore, a visual examination shows no defects on the upper face of the surface layer due to telegraphing of asperities of the support.

[0066] The floor covering thus obtained also complies with FAR 25.853 standards in terms of fire resistance, which makes its use possible in aircraft.

[0067] The dimensional stability results according to EN 434 standards are also very satisfactory. Walking comfort of the floor covering thus obtained is very satisfactory, the non-woven textile layer giving it good cushioning.

[0068] It can be seen from the foregoing that the described embodiments clearly provide a multilayer structure for the production of a floor covering, particularly for passenger transport vehicles, having good fire-resistant properties, while having very good durability and good properties of cleaning and dimensional stability. In particular, the described embodiments make it possible to obtain a floor covering complying with FAR 25.853 standards.

Example 2

[0069] A multilayer structure (1) is produced, similar to example 1.

[0070] Said multilayer structure (1) successively comprises: [0071] A transparent upper wear layer (2) of calendered PVC 0.45 mm thick [0072] A printed decorative film (7) of PVC 0.3 mm thick. The decorative film is printed by digital printing then complexed onto the upper wear layer by a hot lamination process. [0073] A first polyurethane glue layer (3) 35 g/m.sup.2 [0074] A woven reinforcement (4) of glass fibers of 68 Tex. The reinforcement has a plain weave, a surface weight of 219 g/m.sup.2, a thickness of 0.2 mm, 17.4 warp yarns per centimeters, 13.8 weft yarns per centimeter [0075] A second polyurethane glue layer (5) 90 g/m.sup.2 [0076] A non-woven textile layer (6) of 300 g/m.sup.2 and 3.2 mm thick. The non-woven textile layer is produced from a mixture of polyetherimide fibers and polyester fibers. This non-woven textile layer has an oxygen limiting index of 41.3% (0.413).

[0077] The floor covering thus obtained is sufficiently durable to satisfy the tests of resistance to abrasion and to puncturing according to ISO 9352 (2012) and NF EN ISO 24343-1 (April 2012). Furthermore, a visual examination shows no defects on the upper face of the surface layer due to telegraphing of asperities of the support.

[0078] The floor covering thus obtained also complies with FAR 25.853 standards in terms of fire resistance, which makes its use possible in aircraft.

[0079] The dimensional stability results according to EN 434 standards as well as the walking comfort of the floor covering thus obtained are very satisfactory, the non-woven textile layer giving it good cushioning.

Example 3

[0080] A multilayer structure (1) is produced similar to example 2, the only difference being that the non-woven textile layer (6) has a surface weight of 250 g/m.sup.2 and a thickness of 2.7 mm. The non-woven textile layer is produced from a mixture of aramide fibers and polyacrylate fibers. This non-woven textile layer has an oxygen limiting index of 33.1% (0.331).

[0081] The floor covering thus obtained is sufficiently durable to satisfy the tests of resistance to abrasion and to puncturing according to ISO 9352 (2012) and NF EN ISO 24343-1 (April 2012). Furthermore, visual examination shows no defects on the upper face of the surface layer due to telegraphing of asperities of the support.

[0082] The floor covering thus obtained also complies with FAR 25.853 standards in terms of fire resistance, which makes its use possible in aircraft.

[0083] The dimensional stability results according to EN 434 standards as well as walking comfort of the floor covering thus obtained is very satisfactory, the non-woven textile layer providing good cushioning.