NORRHEDE, Rikard (Valhallagatan 29, Glumslöv, S-261 62, SE)
PERSSON, Hans (Färgarevägen 7, Perstorp, S-284 33, SE)
BABAKR, Irina (Hagastigen 10A, Landskrona, S-261 35, SE)
NORRHEDE, Rikard (Valhallagatan 29, Glumslöv, S-261 62, SE)
| PATENT CLAIMS 1. Composition for adhering a floor material to a base surface, which composition comprises an adhesive substance, characterized in that said adhesive substance is non-hardening, and in that the composition further comprises particulate spacer elements, which spacer elements, by virtue of their particle size, are intended to form a minimum distance between said floor material and said base surface, and wherein said spacer elements, in order to obtain said minimum distance, have an extent within the range 0.1-10 mm along at least one longitudinal axis. 2. Composition according to claim 1 , wherein said spacer elements have a regular or irregular geometry. 3. Composition according to claim 1 or 2, wherein said spacer elements, in order to obtain said minimum distance, have an extent within the range 0.3-8 mm along the said at least one longitudinal axis. 4. Composition according to any one of the precedingclaims, wherein said spacer elements comprise natural and/or synthetic elastic polymer materials, preferably chosen from the group comprising cork, rubber, and mixtures thereof. 5. Composition according to any one of the preceding claims, wherein said spacer elements are hewn, chopped, chipped, ground, granulated or crushed, or combinations thereof. 6. Composition according to any one of the preceding claims, wherein said adhesive substance comprises binder preferably chosen from the group consisting of natural rubber, butyl rubber, chloroprene rubber, urethane rubber, acrylic rubber, silicone rubber, polyisobutylene, polybutadiene, polyisoprene rubber, co-polymer of isoprene and isobutylene, halogenated butyl rubber, nitrile rubber (NBR), polyolefins such as EPM, EPDM, EVA, and recycled rubber, and mixtures thereof. 7. Composition according to claim 6 or 7, further comprising filler, softener and/or tackifier, and optionally additives. 8. Flooring comprising a floor material comprising an underside, and a composition according to claim 1 , arranged against the underside. 9. Flooring according to claim 8, further comprising a protective film arranged over the composition. 10. Method for producing a flooring, comprising the steps of - providing at least one floor material - applying the composition according to claim 1 to said floor material on the underside of the floor material, which underside is intended to be positioned against a base surface. |
Field of the invention
The present invention relates to a composition for adhering a floor material to a base surface; a flooring; and a method for producing a flooring.
Background
Floor materials such as parquet floors and laminate floors may be laid in floating arrangement, wherein the floor material is not fixed to the base surface, and non-floating arrangement, wherein the floor material is fixed to the base surface, for example by the application of glue to the base surface, followed by positioning of the floor material against the glue.
Floating floors often result in high noise levels when the floor in the room is trodden on, so called drum noise. Glued floors may lead to lower drum noise levels but higher footfall noise levels, i.e. the noise from pedestrian traffic in adjoining rooms such as rooms above. Gluing of floors also often leads to an escape of volatile solvent from the glue during laying, and laying with gluing is time-consuming. Furthermore, a glued floor cannot be trodden on directly after laying and, once the glue has hardened, the position of the floor material cannot easily be altered without destroying the floor material.
Document DE 10 2006 030 852 A1 describes floor panels having tongue and groove joints and having adhesive applied to the underside of the floor panels. It is a drawback with such adhesives that, when they are non- hardening, they may flow out in the event of prolonged use of the floor and may result in worse or failed adhesiveness and drum noise damping.
It would be desirable to find new options which do not have the problems of conventional methods. Summary
It is an object of the present invention to solve problems associated with conventional methods.
One object of the present invention is to provide an effective composition for adhering floor material to a base surface, to provide an effective flooring, and to provide a method for producing an effective flooring.
By non-hardening adhesive substance according to the invention is meant substance which is and remains deformable, soft and adhesive, and which does not substantially rigidify or harden as a result of, for example, solvent evaporation, drying or cross linking.
According to a first aspect of the invention, the object is achieved by means of a composition for adhering a floor material to a base surface, which
composition comprises an adhesive substance, characterized in that said adhesive substance is non-hardening, and the composition further comprises particulate spacer elements, which spacer elements, by virtue of their particle size, are intended to form a minimum distance between said floor material and said base surface, and wherein said spacer elements, in order to obtain said minimum distance, have an extent within the range 0.1 -10 mm along at least one longitudinal axis.
Non-hardening adhesive substance may result in that floor material which has been adhered to a base surface maybe released from the base surface even after a very long time. Non-hardening adhesive substance may also result in that floor material may be effectively moved and adjusted during laying. Non- hardening adhesive substance may further result ineffective drum noise damping. In addition, non-hardening adhesive substance may result in that flooring may be trodden on directly after laying, since there is no need to wait for hardening. Non-hardening adhesive substance may be free from volatile organic solvents, for example so-called VOC-free, so that said substance and laying of flooring with said substance may be considered advantageous with regard to, for example, health and the environment. Particulate spacer elements ensure a minimum thickness of the layer thickness of the composition between a floor material and a base surface. When the floor material is subjected to load, the spacer elements obstruct the floor material from being moved downwards against the base surface, with the adhesive substance being ousted. A minimum distance between the floor material and the base surface may thus be satisfied by the choice of particle size of the spacer elements. The particle size of the spacer elements may substantially correspond to the minimum distance between the floor material and the base surface. It is desirable to obtain a layer thickness of the adhesive substance between the floor material and the base surface of 0.1 -10 mm, or for said minimum distance to lie within the range 0.1-10 mm. For this purpose, the spacer elements have an extent within the range 0.1-10 mm along at least one longitudinal axis.
The composition may thus be used to adhere a floor material to a base surface, wherein a predetermined, well-defined and desired layer thickness of the composition may be obtained. Furthermore, the spacer elements may prevent the non-hardening substance from being compressed, or may reduce compression of the non-hardening substance, when the floors are subjected to load such as when trodden on. Furthermore, the spacer elements may prevent reduction of the layer thickness of the composition between a base surface and a floor material and/or outflow of the non-hardening substance, even in the event of prolonged use or load of the floor. The invention thus results in that non-hardening substance may be used for adhering of floor material, or for laying of flooring, without risk of the substance being compressed or deformed and thus, for example, being squeezed out through gaps in floor material, or between floor material, or where the floor material ceases. In addition, the spacer elements allow the composition to be applied in strands, which strands do not cover the whole of the underside of the floor material. That said spacer elements, along at least one longitudinal axis, have an extent within the range 0.1-10 mm may ensure that the layer thickness of the composition, or said minimum distance, essentially does not fall below 0.1-10 mm. For example, it may be ensured that the layer thickness essentially does not fall below 0.1 mm. It will be appreciated, however, that especially when the spacer elements are made of elastic materials, in the event of temporary heavy loading of the floor, the layer thickness may temporarily fall below the extent, for example 0.1 mm, by virtue of the fact that said spacer elements and thus the composition may be temporarily and elastically compressed. When the spacer elements are made of or comprise elastic materials, the spacer elements may give the composition elastic properties.
The spacer elements may result in that floor material is made easier to dismantle.
Said longitudinal axis is the longitudinal axis which, after floor material has been laid, will lie substantially perpendicular to the base surface. It will be appreciated that the longitudinal direction may have another orientation before or during the time that the floor material is laid, but when the floor material is pressed against the base surface during laying, or when the floor is subjected to load after laying, the orientation of the longitudinal direction may be altered to lie substantially perpendicular to the base surface.
0.1 -10 mm may be a suitable layer thickness for a laid flooring. Such a layer thickness leads to good drum noise damping and good adhering of flooring according to the invention to base surface.
Said spacer elements may have an irregular or regular geometry. The spacer elements may thus have a regular geometry which may be, for example, spherical, cubic, cuboid, oval, cylindrical, or parallelogram. Said spacer elements may thus have irregular geometry, for example geometry of the kind which is obtainable when material, for example, is hewn, ground, crushed, chipped, granulated or chopped, or combinations thereof. For example, the spacer elements may be granulate. For example, the spacer elements may be elongated, flake-shaped or broadened in shape.
The composition may also comprise a mixture of spacer elements which have irregular geometry and spacer elements which have regular geometry.
Said spacer elements for obtaining said minimum distance may have an extent within the range 0.3-8 mm in at least one direction.
Said minimum distance may thus substantially lie within the range 0.3-8 mm, such as 0.6-7 mm. It may be preferred that said extent and/or said minimum distance lie(s) within the range 0.5-5 mm, for example 1 -4 mm, or 2-4 mm.
Said spacer elements may comprise natural and/or synthetic elastic polymer materials, preferably chosen from the group comprising cork, rubber, and mixtures thereof. That said spacer elements may comprise elastic material may allow springing of the flooring when trodden on. In addition, it may result in that effective drum noise damping is obtained. Where different spacer elements have different size, it may also allow the spacer elements to be compressed to different degrees between the floor material and the base surface, so that a uniform layer thickness is obtained between the floor material and the base surface.
Said spacer elements may be hewn, chopped, chipped, ground, crushed or granulated, or combinations thereof. Said spacer elements may thus be effectively produced from, for example, recycled rubber material, polymer material or cork, which material may be granulated, hewn, chopped, chipped, ground or otherwise finely divided into particulate spacer elements.
Said adhesive substance which is non-hardening may comprise binder preferably chosen from the group consisting of natural rubber, butyl rubber, chloroprene rubber, urethane rubber, acrylic rubber, silicone rubber, polyisobutylene, polybutadiene, polyisoprene rubber, co-polymer of isoprene and isobutylene, halogenated butyl rubber, nitrile rubber (NBR), polyolefins such as EPM, EPDM, EVA, and recycled rubber, and mixtures thereof. Non- hardening adhesive substance having suitable properties, for example deformability and softness, may thus be obtained.
The composition may further comprise filler, softener and/or tackifier, and possibly additives. Non-hardening adhesive substance having suitable deformability, softness and tackiness may thus be obtained. Said filler may be, for example, China clay and/or chalk, and/or other suitable filler. Suitable properties may thus be obtained in the substance.
Said softener and/or tackifier may be chosen from the group comprising oil, liquid polyisobutylene and resin, or mixtures thereof. Suitable softness and tackiness of the substance may thus be chosen.
Said possible additives may be, for example, antioxidants, stabilizers and/or pigment. According to a second aspect of the invention, the object is achieved by means of flooring comprising a floor material comprising an underside, and a composition arranged against the underside. A flooring having the properties given by the composition may thus be obtained.
The floor material may be, for example, of the board or slab type. For example, the floor material may be boards such as parquet boards, wooden boards, laminate boards, particle boards, polymer boards, tiles, clinker, bricks, concrete slabs, or stone slabs, or combinations thereof.
Where appropriate, for example where the floor material is of the board or slab type, the floor material may comprise tongue and groove type joints or click joints for the connection of floor material.
The flooring may comprise a protective film arranged over the composition. Before it is laid, the floor material may thus be effectively handled and/or transported and protected from dust and dirt. Furthermore, several floorings may be stacked one on top of the other without sticking together, which may be a great advantage in terms of warehousing and transport.
The spacer elements make stacking of floorings effective, since the spacer elements prevent the non-hardening adhesive substance from flowing out or being compressed in an unwanted manner, despite the fact that flooring right at the bottom or far down in a stack of several floorings may be subjected to high load. Said spacer elements thus allow very effective transport, warehousing, handling and storage of said floorings.
According to a third aspect of the invention, the object is achieved by means of a method for producing flooring, comprising the steps of providing at least one floor material; and applying the composition according to the invention to said floor material on the underside of the floor material, which underside is intended to be positioned against a base surface. Flooring may thus be produced, which flooring comprises the composition according to the invention, or according to claim 1 and claims dependent thereon. The composition may be applied to said floor material in the form of strands. The application of the composition in strands may be an effective way of applying the composition and, furthermore, strands may be a suitable shape for allowing effective laying of flooring. The application of the composition in strands also results in lower consumption of the composition per square metre of floor area, compared with if the composition is applied over substantially the whole of the underside of the floor material. In addition, better footfall noise damping is obtained compared with glued floors.
Parts of the above discussions and descriptions concerning the composition are also relevant with regard to the flooring and the method for producing the flooring. Reference is herewith made to these discussions and descriptions.
Description of drawings
Figure a schematically illustrates a section through a composition according to the invention comprising fixing substance and spacer elements, which spacer elements substantially have the same size and geometrical shape.
Figure 1 b schematically illustrates a section through a composition according to the invention comprising fixing substance and spacer elements, which spacer elements substantially have different size and geometrical shape.
Figure 2a illustrates flooring laid on a base surface, which flooring comprises floor material and composition according to Figure 1 a.
Figure 2b illustrates flooring laid on a base surface, which flooring comprises floor material and composition according to Figure 1 b. Figure 3 illustrates a flooring viewed in the longitudinal direction of the floor material.
Figure 4 illustrates flooring laid on a base surface, which flooring comprises floor material and composition, which composition comprises spacer elements having a spread or variation relating to said extent.
Figure 5 illustrates a so-called Melt Viscosity Index (MVI) curve for a substance according to the invention.
Detailed description
The invention will now be described in greater detail and, in particular, preferred embodiments and variants of these will be described. The descriptions aim to be illustrative and descriptive and should not in any way be regarded as limiting of the scope of the invention. The figures are schematic and not all details are illustrated, nor are all illustrated details required to be necessary for the invention. A preferred embodiment will now be discussed with reference to Figures 1 a and 1 b. Figures 1a and 1 b show schematic representations of the
composition 1 . The composition comprises adhesive substance 2 and spacer elements 3, whereof just one spacer element of the plurality of spacer elements is identified in the respective figure. From Figure 1 b it may be seen that the spacer elements may have different geometrical shapes. Common to all spacer elements in Figures 1 a and 1 b is that they all have an extent 4, illustrated by the arrows beside each spacer element, within the range 0.1-10 mm along at least one longitudinal axis. In these specific examples, the extent is substantially the same for all spacer elements. It will be appreciated that the extent may have a spread and variation. It may be the case that a plurality of spacer elements have substantially equal extent 4, which extent forms said minimum distance, since a plurality of particles may be jointly present in the adhesive substance, which particles may be substantially smaller than the spacer elements, in which case these particles do not form said minimum distance.
It will be appreciated that different spacer elements in the same adhesive substance may have a varying size, including with respect to said at least one longitudinal axis. All the same, advantages with the invention may be effectively achieved, especially where the spacer elements are elastic. The spacer elements may thus have a spread or variation with respect to size and/or said extent. It will also be appreciated that the composition may further comprise particulate material which substantially is smaller than said extent, which particulate material will not help to form said minimum distance. It will also be appreciated that the composition may further comprise those spacer elements which have an extent which is larger than a minimum distance, which spacer elements, by virtue of their elasticity, may be compressed to the same height as other spacer elements when the floor material is laid or subjected to load.
For example, spacer elements may be obtained by fractionation of particulate material by means of, for example, screening, wherein a fraction with desired sizes of the spacer elements may be obtained. By such fractionation, particulate material which substantially is larger and/or smaller than the desired minimum distance may be removed.
Advantages may be obtained if the spread of the extent is low. A large part of the spacer elements may accordingly help to form said minimum distance between the floor material and the base surface.
Floorings 5 comprising the compositions 1 according to the above
discussions relating to Figures 1 a and 1 b are now discussed with reference to Figures 2a and 2b. Figure 2a corresponds to Figure 1 a, and Figure 2b corresponds to Figure 1 b. The flooring also comprises a floor material 6, which in this case is a laminate board. The spacer elements 3 in both Figure 2a and Figure 2b have at least one extent 4 within the range 0.1 -10 mm along a longitudinal axis lying perpendicular to the base surface 7, and in these examples the extent 4 is about 2 mm. It will especially be noted that all spacer elements 3 in all longitudinal directions have an extent which is as large as or larger than said at least one extent 4. In the spacer elements illustrated by Figure 2a, the extent is equally large in all directions. The spacer elements illustrated in Figure 2a are substantially spherical and, in the case of spherical geometry, said extent along at least one longitudinal axis is corresponded to by the diameter. In the case of cubic geometry, said extent along at least one longitudinal axis is corresponded to by the length of the side of the cube. It will be appreciated that in the example having a flake-shaped or flat geometry, or a geometry which has a large broadened base and an, in relation to the dimensions of the base, small height at right angles to the base, the height will obtain said minimum distance between the floor material and the base surface, since such spacer elements will position themselves with their base substantially in parallel with the base surface.
In these specific examples, the spacer elements 3 are made of rubber. It will be appreciated from Figures 2a and 2b that even when the floor material is trodden on, or otherwise subjected to load, the spacer elements 3, by virtue of their particle size, will form a minimum distance between the floor material 6 and the base surface 7. Since the spacer elements in these examples are made of rubber, they will be compressed somewhat when the floor is subjected to load, but the density of the spacer elements in the composition and the rigidity or elasticity of the spacer elements satisfy the desired minimum distance. Said spacer elements ensure that the adhesive substance 2 is not squeezed out from under the floor material 6 despite the non- hardening nature of the substance. Had the spacer elements not existed, the substance 2 would have been compressed when the floor material 6 was subjected to load, in which case the substance 2 would be squeezed out, for example, into spaces between floor material or where the floor material 6 ceases, for example beside a wall should the floor material be laid up to a wall. Those properties of the flooring which derive from the substance would thus be lost or reduced, such as adhering to the base surface and drum noise damping.
In this example, the base surface 7 is a concrete slab. It will be appreciated that the base surface may be constituted by any suitable materials, for example the base surface may be a cement or concrete floor, a sub-floor of wood or wood fibres with binder, for example particle board, or a framework of, for example, wood or metal, or combinations thereof. The base surface may also be constituted by a pre-existing floor, for example a mat or a floor consisting of boards or slabs.
Note that it may be seen from Figure 2b that all spacer elements have positioned themselves such that said longitudinal axis is perpendicular to the base surface. Note also that several of the spacer elements in Figure 2b have dimensions which are larger than the extent 4, but that these dimensions, as a result of the geometry of the spacer elements, are not perpendicular to the base surface and do not help to form said minimum distance.
A flooring 5 according to one embodiment of the invention is now discussed with reference to Figure 3. The flooring 5 comprises a floor material 6, which in this specific example is a clinker slab. On the floor material 6, the composition 1 is arranged in strands. For example, the number of strands may be , 2, 3, 4, 5, 6, 7, 8, 9 or 10 strands per floor material, or more than 10 strands per floor material. According to this example, the strands have a height from the floor material which is larger than said minimum distance. Since the strands are arranged at a distance apart, the strands, when they are laid, or when the flooring is subjected to load after laying, may be compressed until the spacer elements 3 form and secure said minimum distance. The flooring has a protective film 8 arranged over the composition. Thus the composition is protected and unwanted contact between the composition and other material is avoided. When the flooring is to be fixed to a base surface, the protective film is simply removed, whereupon the composition may adhere to the base surface as the floor material is laid. According to this example, a protective film is arranged over the composition, but several protective films may be provided, for example one protective film per strand for those cases in which the composition is arranged in a plurality of strands. According to this example, the strands are continuous along substantially the full extent of the floor material, but it will be appreciated that the strands may also be intermittent and even be so short that they may be likened to dots.
The strands may be arranged substantially in parallel with the longitudinal direction of the floor material.
It will be appreciated that strands are just one conceivable embodiment. Substantially the whole of the underside of the floor material may be coated with composition. Expediently, the composition then has a thickness, even before the flooring is laid, corresponding to said minimum distance. For example, 80% or less of the underside of the floor material may be coated with composition according to the invention.
Floorings 5 comprising the composition 1 will now be discussed with reference to Figure 4. The flooring also comprises a floor material 6, which in this case is a parquet board. The spacer elements 3a-e have at least one extent 4 within the range 0.1-10 mm along a longitudinal axis lying
perpendicular to the plane of the base surface 7. The floor material as illustrated in Figure 4 is under load.
In this example, the spacer elements 3a-e are constituted by cork granules of varying size. Since the diagram is schematic, the granules are depicted as spheres, since in reality they may be non-uniform and deviate from the spherical shape and may be considered to have an irregular geometry. It will be appreciated that the spacer elements 3a-e could have had a regular geometry, such as a spherical geometry, and the discussions with reference to Figure 4 would still have been relevant. It will be noted that the substance 2 contains cork granules which are so small that they do not help to obtain said minimum distance 9, which cork granules may be considered not to be spacer elements. It will especially be noted that all spacer elements 3 which help to obtain said minimum distance 9 have in all longitudinal directions an extent which is as large as or larger than said at least one extent 4. Before the flooring 5 was laid and subjected to load, the spacer elements a-c had extents 4 which were larger than the minimum distance 9. Thus the extent 4 for the spacer elements 3a-e has variation and yet effective obtaining of the minimum distance 9 is still achieved.
It will be appreciated that the substance between the floor material 6 and the base surface 7, or the joint, has elastic properties, since the spacer elements in this example are elastic. The substance may be characterized, for example, with the aid of melt viscosity measurements, so-called MVI measurements (Melt Viscosity Index). For the laying of flooring according to the invention, an MVI curve according to Figure 5 may be suitable. Where appropriate, a pressure of 5 kg has been applied and a nozzle of 2 mm diameter has been used. It will be appreciated that the MVI curve is only one example of a suitable substance, and that values outside the curve may also be suitable.
The composition may comprise up to 50% with respect to the volume of spacer elements. It may be preferred that the composition comprises 1 -50% with respect to the volume of spacer elements.
According to one example, a substance according to the invention may comprise:
10-30% by weight binder, for example rubber raw material;
50-70% by weight filler, for example non-organic filler;
5-20% by weight softener, extender, tackifier, and/or rheology modifier; 1 -10% by weight elastic spacer elements; and 0.1 -2% by weight additives, for example antioxidants and/or
dispersants.
With the substance according to the invention, a semi-floating floor may be laid, or a floor which adheres to the base surface but which is allowed to vary in size and move in relation to the base surface, for example as a result of swelling or shrinkage of the floor material resulting from variations in air humidity. The substance may be arranged in strands which have a height at right angles to the floor material which is larger than the minimum distance between the floor material and the base surface of the laid floor, and the strands, when the floor is laid, are compressed substantially to the minimum distance.
The spacer elements may be distributed substantially homogeneously in the adhesive substance.
Examples
Tests have been conducted wherein it has been measured that floors laid with flooring according to the invention, with floor material of the laminate floor type, result in drum noise damping of 3-25 dB compared with when the same floor material has been laid in floating arrangement. In addition, tests have been done showing that no increase in VOC has been measured in the laying of flooring according to the invention compared with floors laid in floating arrangement on a base surface. The same floor materials was used in the comparative tests.