METHOD OF MANUFACTURING A FLOOR COVERING

• US 20140147585A1
• Filed: 11/05/2013
• Published: 05/29/2014
• Est. Priority Date: 11/23/2012
• Status: Abandoned Application

• Current Assignee: James Halstead, PLC
• Original Assignee: James Halstead, PLC
• Inventors: Smith, Robert N.B.
• Application Number:
  US14/072,037
• Publication Number:
  US 20140147585A1
• Time in Patent Office: Days
• US Class Current: 427/202
• CPC Class Codes: B29D 99/0057 Producing floor coverings
• CPC Class Codes: B32B 2255/02 on fibrous or filamentary layer
• CPC Class Codes: B32B 2260/046 Synthetic resin
• CPC Class Codes: B32B 2262/101 Glass fibres
• CPC Class Codes: B32B 2266/0235 Vinyl halide, e.g. PVC, PVDC, PVF, PVDF
• CPC Class Codes: B32B 2307/102 Insulating
• CPC Class Codes: B32B 2307/40 having particular optical properties light or UV resistant B32B2307/71
• CPC Class Codes: B32B 2307/412 Transparent
• CPC Class Codes: B32B 2307/554 Wear resistance
• CPC Class Codes: B32B 2307/744 Non-slip, anti-slip
• CPC Class Codes: B32B 2471/00 Floor coverings B32B2419/04 takes precedence
• CPC Class Codes: B32B 2471/02 Carpets
• CPC Class Codes: B32B 27/065 of foam
• CPC Class Codes: B32B 27/08 of synthetic resin
• CPC Class Codes: B32B 27/12 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 27/20 using fillers, pigments, thixotroping agents
• CPC Class Codes: B32B 27/304 comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF
• CPC Class Codes: B32B 27/40 comprising polyurethanes
• CPC Class Codes: B32B 5/18 characterised by features of a layer of foamed material
• CPC Class Codes: B32B 5/20 foamed in situ
• CPC Class Codes: B32B 5/245 : another layer next to it being a foam layer
• CPC Class Codes: D06N 2209/025 : Insulating, sound absorber
• CPC Class Codes: D06N 2209/0807 : Coloured
• CPC Class Codes: D06N 2209/0815 : on the layer surface, e.g. ink
• CPC Class Codes: D06N 2209/106 : Roughness, anti-slip, abrasiveness
• CPC Class Codes: D06N 2211/066 : Floor coverings
• CPC Class Codes: D06N 3/005 : obtained by blowing or swelling agent
• CPC Class Codes: D06N 3/0063 : Inorganic compounding ingredients, e.g. metals, carbon fibres, Na2CO3, metal layers; Post-treatment with inorganic compounds
• CPC Class Codes: D06N 3/06 : with polyvinylchloride or its copolymerisation products surface treatment or foaming for floor coverings D06N7/0007
• CPC Class Codes: D06N 3/08 : with a finishing layer consisting of polyacrylates, polyamides or polyurethanes or polyester
• CPC Class Codes: D06N 7/001 : obtained by mechanical embossing
• CPC Class Codes: D06N 7/0055 : Particulate material such as cork, rubber particles, reclaimed resin particles, magnetic particles, metal particles, glass beads

Abstract

Decorative heterogeneous floor covering has sound attenuation effect with an acoustic impact sound reduction of at least about 15 decibels and sustainable sip-resistance properties. The method comprising the steps of: (a) providing a print layer comprising a print decoration/design thereon; (b) providing a wear layer over the print layer to provide a print/wear layer intermediate; and (c) providing a foam backing layer on the intermediate, the backing layer being capable of providing the sound attenuation effect. Between steps (a) and (b), the method has inverting the print/wear layers intermediate before applying the backing layer to a reverse side/base thereof.

Claims

1. A method of manufacturing a decorative heterogeneous floor covering comprising a sound attenuation effect with an acoustic impact sound reduction of at least about 15 decibels and sustainable slip-resistance properties, the method comprising the steps of:

a) providing a print layer comprising a print decoration/design thereon;

b) providing a wear layer over said print layer to provide a print/wear layer intermediate; and

c) providing a foam backing layer on the intermediate, the backing layer being capable of providing said sound attenuation effect;

wherein between steps (a) and (b), the method comprises inverting the print/wear layers intermediate before applying the backing layer to a reverse side/base thereof.

2. The method according to claim 1, wherein the wear layer is applied as a gel which is heat cured.

3. The method according to claim 2, wherein prior to processing (curing) of the wear layer, step (b) comprises scatter application of a particulate material.

4. The method according to claim 3, wherein the particulate material is allowed to at least partially embed itself in the unprocessed (gel) wear layer.

5. The method according to claim 1, wherein the method comprises providing the wear layer with a surface finish.

6. The method according to claim 5, wherein the surface of the wear layer is embossed.

7. The method according to claim 6, wherein the emboss comprises a combination of micro- and macro-scale emboss patterns, which range from about 30 μ

m to about 160 μ

m, respectively, in depth.

8. The method according to claim 5, wherein the surface finish on the wear layer is applied after the application and processing of the backing layer.

9. The method according to claim 3, wherein the particles of the particulate material have an average size of between about 0.50-0.75 mm across their widest points.

10. The method according to claim 3, wherein the particles are distributed across the covering in an amount of about 100-300 g/m².

11. The method according to claim 1, wherein the backing layer comprises an acoustic impact sound reduction of at least about 19 decibels.

12. The method according to claim 1, wherein the backing layer is applied as a liquid.

13. The method according to claim 12, wherein subsequent processing of the backing layer comprised blowing and curing steps.

14. The method according to claim 13, wherein during blowing, a blowing agent and process temperature is increased or decreased to change the density, stiffness and foam thickness.

15. The method according to claim 1, wherein the method further comprises the addition of a reinforcing layer.

16. The method according to claim 15, wherein the reinforcing layer provides the initial or starting component of the flooring.

17. The method according to claim 16, wherein the print layer is applied to an upper surface of the reinforcing layer.

18. The method according to claim 17, wherein the backing layer is applied to an underside of the reinforcing layer.

19. The method according to claim 15, wherein the reinforcing layer comprises glass fibre.

20. The method according to claim 19, wherein the reinforcing layer is encapsulated and heat cured.

21. The method according to claim 1, wherein a coating is added to the wear layer.

22. The method according to claim 20, wherein the coating comprises a substantially 100% radiation curing lacquer system.

23. The method according to claim 21, wherein the coating comprises a quantity of a particulate material having a high coefficient of friction.

24. The method according to claim 21, wherein the coating comprises a dry film thickness in the region of about 15-25 μ

m.