The object of the invention is a foamed PVC flocked moulding and a method for forming said moulding.

A plastic is known - foamed PVC (also referred to as polyvinyl chloride, PVC), from which various desired shapes can be formed. It is a commercially available material, e.g. in the form of boards.

A surface finishing technique referred to as flocking is known.

Flocking consists in covering a surface with fine textile plastic fibres. It produces a pile-like effect with a uniform surface, the so-called flock. Flocking has a number of properties that are advantageous in use: it does not attract dust (anti-static property), does not absorb moisture (anti-condensation), has high resistance against abrasion and mechanical damage (produced e.g. during vacuuming - and by strokes of the vacuum brush), high resistance to soiling, and, in addition to the above - high quality of design and aesthetics of the surface. For these reasons, the flock is highly recommended for finishing skirting boards intended for all types of interiors.

The flocking technique is known - it is based on a well-tested production process used for many years. To put it simply, in the process of flocking, an object (e.g. a moulding) is being covered with appropriate adhesives, and then fine fibres are applied on the surface, to create a homogeneous and compact durable structure. Apart from the interior design industry, flocking is used e.g. in the automotive industry (e.g. flocking of door seals exposed to damage and friction), in the production of everyday objects - that are exposed to damage and scrapes (e.g. clothes hangers, containers, mattresses), as well as in thefurniture making and clothing sector. Foamed PVC mouldings with flocked surface (flocked mouldings), e.g. skirting boards, are neither known nor commercially available.

During assembly of mouldings of this type in a room (e.g. along the walls), it is often necessary to apply the mouldings on the external or internal corners, depending on the construction of the room. A known solution used in such cases is to make a partial incision on the moulding with a sharp tool (e.g. a carpet knife) on the side opposite to the flock, thus allowing for the moulding to be bent. However, this involves the risk of impairing the continuity of the flocked surface, which negatively affects the aesthetics and performance of the moulding. As an alternative, the moulding can be cut in full and a corner can be made using two separate pieces of the moulding. This variant makes it necessary to cut the flocked surface, as well as to perform multiple fittings of the elements to the corner - assuming that a perfect adherence of the moulding to the walls is desired.

Therefore, it is an object of the present invention to propose novel, durable, advantageous in use and aesthetically pleasing finishing mouldings made of foamed PVC with a flocked surface.

A further object of the present invention is to propose a method for forming PVC flocked mouldings free from the above shortcomings, and in particular without the need to cut them, so that there is no risk of breaking or destroying the flocked surface, while allowing to achieve in a simple way a perfect fit, and, accordingly, perfect adherence of the moulding to the surface in the corners.

Surprisingly, it has been found that said objects can be achieved by producing a flocked moulding by methods known in the art and by properly heating the flocked moulding in the location of the prospective bend, hot bending the moulding, in particular by applying it closely to the surface to be covered (e.g. a wall), and subsequently cooling the moulding in this state to achieve rigidity of the shape conferred to it.

The object of the present invention is a foamed PVC moulding having at least one surface covered with flock.

The object of the present invention is also a method for forming a foamed PVC flocked moulding, characterised in that it comprises the step of locally heating the moulding where it is to be bent until the moulding becomes flexible in this location, the subsequent step of bending the moulding in this location and the step of cooling the moulding until the bent moulding becomes rigid again.

Preferably, in the step of locally heating the moulding, a heat gun is used for heating that produces a jet of hot air, which jet of hot air from the heat gun is directed to the place on the moulding that is intended to be bent.

Preferably, a heat gun is used producing a jet of air with the temperature of 100- 200°C or a heat gun producing a jet of air with the temperature o 450°C.

Preferably, in the step of locally heating the moulding, the side opposite the flocked side, the flocked side or both said sides are heated.

Preferably, in the step of locally heating the moulding, the moulding is heated to a temperature between 200 and 600°C.

Preferably, the step of locally heating the moulding takes between 10 and 100 seconds, preferably between 30 and 90 seconds.

Preferably, the step of bending the moulding in the location to be bent involves manual bending of the moulding.

Preferably, the step of bending the moulding in the location to be bent involves forming the moulding by applying it, as closely as possible, to the outer object, in particular to the surface of the corner of the wall of the room.

In a preferred embodiment, in the step of bending the moulding in the location to be bent, the moulding is additionally pressed in the location to be bent with a pressing element, preferably with a circular, cylindrical stick.

Heating from the side of the flock prevents the formation of cracks on the flocked surface.

The method according to the present invention allows for perfect bending and fitting of the moulding to the corners, both the inner and outer ones, which results in perfect adherence of the moulding to the surface of e.g. a wall. At the same time, the flocked surface of the moulding remains intact and continuous (in particular - with no cracks), with all of it achieved without the use of cutting tools. Preferred embodiment of the invention

Producing a foamed PVC flocked moulding.

Produced or purchased foamed PVC boards are used, to make, e.g. by cutting the moulding, for example, mouldings with the following heights: 60mm, 80mm, 100mm, 120mm (but other heights are also conceivable), with the following thicknesses: 5mm, 8mm (but other thicknesses are also conceivable, e.g. 6mm, 7mm, 9mm, 10mm or 19mm), with the commercial length of 2000 mm and various cross-sections.

Then, the surface of said mouldings is flocked using a known method - as referred to in the flocking process; simply put, the moulding is covered with suitable adhesives, and then fine fibres are applied to the surface that form a homogeneous and compact durable structure. Thus, a flocked moulding is obtained.

Forming a foamed PVC flocked moulding.

In a preferred embodiment of the method according to the invention described below, flocked skirting boards made of foamed PVC produced as described above are bent. However, the method described can be applied just as well to flocked foam PVC mouldings other than the mouldings referred to above.

When assembling mouldings of this type in a room, it is important to preserve their properties (which means that the flock should not be damaged or destroyed), and to achieve a perfect fit/adherence of the mouldings to the surface of the wall or floor, especially in the corners of the room.

First, the mouldings should be conditioned in a given room at 18°C for at least 4 h. A heat gun is used to properly form the angles, which is used to carefully heat the moulding in the selected location where a corner is intended to be made, from a distance (e.g. the recommended distance for a 450°C heat gun is approx. 15 cm) until the moulding becomes flexible in this location (i.e. for the period of about a dozen or several dozens of seconds ). Subsequently, the moulding is formed on the corner, e.g. on the wall, by applying the flexible moulding to the wall as closely as possible and bending it - and obtaining as a result the right bending angle of the moulding, adapted to this section of the wall. Then it is necessary to wait approx. 30 seconds until the moulding cools down. The moulding then loses its flexibility and becomes rigid again, which solidifies the shape conferred to it. In the inner corners, it is good to use a piece of a round small stick, pressing it evenly against the mouldings from the side of the flock in the inner corner. Other pressing tools/elements can be used.

A heat gun with lower power (e.g. producing a jet of air with the temperature of 100- 200°C) can be used by directing the jet of air onto the moulding from a suitably shorter distance. Similarly, a heat gun with greater power (e.g. producing a jet of air with the temperature of 500°C) can be used by directing the jet of air onto the moulding from a suitably greater distance.

It is important not to destroy (melt) the flock during the heating.

Depending on the needs, in particular on the desired shape of the moulding, the moulding can be heated from the side opposite to the flock, from the side of the flock or from both sides. Appropriate heating of the strip from the side of the flock prevents the formation of cracks on the flocked surface.

A known moulding assembly adhesive is used to attach the mouldings to the wall, e.g. applied with a manual gun with assembly adhesive or a gun with hot melt adhesive.

In general, in the step of locally heating the moulding, the moulding is heated to a temperature which depends on the device used for heating, which must be at least 200°C and up to 600°C, with the proviso that the distance from the moulding must be chosen depending on the heating temperature.

It is important for the temperature resistance of the flock to be approx. 240-250°C.

Similarly, the step of locally heating the moulding typically takes approx. 10-100 seconds, depending on the temperature used to heat the moulding and on its thickness (different heat guns have different temperatures). For example, at a heating temperature of approx. 450°C, it takes about 30-40 seconds, with the heat gun held at a distance of approx. 20 cm from the moulding.