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Title:
PVC BASED, LAYERED FLOOR COVERING
Document Type and Number:
WIPO Patent Application WO/2020/070646
Kind Code:
A1
Abstract:
A PVC-based, layered floor covering, comprising the following successive layers: a. a first PVC layer; b. a layer of a first PVC permeated textile product; c. a second PVC layer; d. a layer of a second PVC permeated textile product; e. a decorative layer comprising a polymer layer; f. a wear layer comprising a transparent polymer layer; wherein the first PVC layer has a thickness of more than 2.0 mm, consists of foamed PVC and provides the underside of the floor covering.

Inventors:
MARIJSSE FREDERIK (BE)
VAN VLASSENRODE KRISTOF (BE)
Application Number:
PCT/IB2019/058347
Publication Date:
April 09, 2020
Filing Date:
October 01, 2019
Export Citation:
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Assignee:
IVC BVBA (BE)
International Classes:
B32B5/02; B32B5/18; B32B5/20; B32B5/24; B32B27/06; B32B27/08; B32B27/12; B32B27/30; D06N7/00; E04F15/10
Domestic Patent References:
WO2015005716A12015-01-15
WO2013178561A22013-12-05
Foreign References:
JP2018003508A2018-01-11
EP2481848A12012-08-01
Attorney, Agent or Firm:
VAN STEENLANDT, Wim (BE)
Download PDF:
Claims:
Claims

1. A PVC-based, layered floor covering, comprising the following successive layers:

a. a first PVC layer;

b. a layer of a first PVC permeated textile product ;

c. a second PVC layer;

d. a layer of a second PVC permeated textile product ;

e. a decorative layer comprising a polymer layer;

f. a wear layer comprising a transparent polymer layer;

wherein the first PVC layer has a thickness of more than 2.0 mm, consists of foamed PVC and provides the underside of the floor covering.

2. A floor covering in accordance with claim 1 , wherein the density of the first PVC layer is in the range of 0.25 to 1.00 g/cm3.

3. A floor covering in accordance with claim 1 or 2, wherein the PVC of the first PVC layer is a soft PVC.

4. A floor covering in accordance with one of the preceding claims, wherein the PVC of the second PVC layer is a soft PVC.

5. A floor covering in accordance with one of the preceding claims, wherein the PVC of the second PVC layer is unfoamed.

6. A floor covering in accordance with one of claims 1 to 4, wherein the PVC of the second PVC layer is foamed.

7. A floor covering in accordance with one of the preceding claims, wherein the first textile product is partially impregnated with the PVC of the second PVC layer and the first textile product is partially impregnated with the PVC of the first PVC layer.

8. A floor covering in accordance with one of claims 1 to 6, wherein the first textile product is completely permeated with the PVC of the second PVC layer.

9. A floor covering in accordance with one of the preceding claims, wherein the second textile product is permeated with a PVC that is different from the PVC of the first and the second PVC layer.

10. A floor covering in accordance with one of the preceding claims, wherein the polymer of the decorative layer is PVC.

11. A floor covering in accordance with claim 10, wherein the polymer of the decorative layer is foamed PVC.

12. A floor covering in accordance with claim 10, wherein the polymer of the decorative layer is unfoamed PVC.

13. A floor covering in accordance with one of the preceding claims, wherein the polymer of the wear layer is PVC.

14. A floor covering in accordance with one of the preceding claims, wherein the floor covering is between 2 and 4 meters wide and 20 to 30 meters long.

15. A floor covering in accordance with one of the preceding claims, wherein the floor covering is provided in rolled-up form.

16. The method for producing a floor covering in accordance with one of the preceding claims, comprising the following successive steps:

g. the provision of a first PVC permeated textile product with that corresponds to the second textile PVC permeated product of the floor covering in accordance with one of the preceding claims;

h. the application, to a first side of the permeated textile product, of the polymer layer of the decorative layer;

i. the application, to the free side of the polymer layer of the decorative layer, of the polymer layer of the wear layer,

j. the application, to the second side of the permeated textile product, of a PVC layer that corresponds to the second PVC layer of the floor covering in accordance with one of the preceding claims; k. the application of a further textile product to this PVC layer, which textile product corresponds to the textile product of the first textile product impregnated with PVC of the floor covering in accordance with one of the preceding claims;

L. the application to the further textile product of a layer of foamable or foamed PVC that is to provide the first PVC layer of the floor covering in accordance with one of the preceding claims, which foamable or foamed PVC is to have a thickness of more than 2 mm in a foamed state.

17. The method in accordance with claim 16, wherein the provision of a textile product permeated with a first PVC comprises the following steps::

a.i.- the provision of a textile product;

a.ii.- the permeation of this textile product with a first PVC plastisol; a.iii.- the pregelling of the first PVC plastisol.

18. The method in accordance with one of claims 16 or 17, wherein the application to the second side of the permeated textile product of a PVC comprises the following steps:

d.i.- the application, to the second side of the permeated textile product, of a PVC plastisol;

d.ii.- the pregelling of this PVC plastisol.

19. The method in accordance with claim 18, wherein step e takes place before step d.ii, and wherein the PVC penetrates into the further textile product in order to permeate the further textile product.

20. The method in accordance with one of claims 16 to 19, wherein the application to the further textile product of a layer of foamable or foamed PVC that is to provide the first PVC layer of the floor covering in accordance with one of the preceding claims comprises the following steps:

f.i.- the application to the further textile product of a layer of foamable or foamed PVC plastisol;

f.ii.- optionally, the pregelling of this PVC plastisol.

21. The method in accordance with claim 16, comprising the steps: a. the provision of a textile product impregnated with a first PVC material that corresponds to the second PVC permeated textile product of the floor covering in accordance with one of claims 1 to 15, comprising

i. the provision of a textile product;

ii. the impregnation of this textile product with a PVC plastisol; iii. the pregelling of the first PVC plastisol;

b. the application, to a first side of the impregnated textile product, of the polymer layer of the decorative layer;

c. the application, to the free side of the polymer layer of the decorative layer, of the polymer layer of the wear layer,

d. the application of a PVC layer that corresponds to the second PVC layer of the floor covering in accordance with one of claims 1 to 15, comprising i. the application, to the second side of the impregnated textile product, of a PVC plastisol layer;

ii. the pregelling of this PVC plastisol.

e. the application of a further textile product to this PVC layer, which textile product corresponds to the textile product of the first PVC permeated textile product of the floor covering in accordance with one of the preceding claims;

f. the application to the further textile product of a layer of foamable or foamed PVC that is to provide the first PVC layer of the floor covering in accordance with one of claims 1 to 15, which foamable or foamed PVC is to have a thickness of more than 2 mm in a foamed state, comprising i. the application to the further textile product of a layer of a foamable PVC plastisol, which is to have a thickness of more than 2 mm in a foamed and gelled state;

ii. optionally, the pregelling of this PVC plastisol;

g. the gelling of all PVC plastisols.

22. The method in accordance with one of claims 17 to 20, wherein after step g, a lacquer layer is applied to the wear layer.

23. The method in accordance with one of claims 18, 21 or 22, wherein step e takes place before step d.ii, and wherein the PVC plastisol of step d.i penetrates into the further textile product in order to permeate the further textile product.

24. The method in accordance with one of claims 20, 21 or 22, wherein during step f, the PVC plastisol penetrates into the further textile product in order to permeate the textile product.

25. The method in accordance with one of claims 16 to 24 wherein during step b, a decorative pattern is applied.

26. The method in accordance with one of claims 16 to 25, wherein in step b, the polymer of the decorative layer is a PVC plastisol and wherein step b comprises the pregelling of this PVC plastisol.

27. The method in accordance with one of claims 16 to 26, wherein in step c, the polymer of the decorative layer is a PVC plastisol and wherein step c comprises the pregelling of this PVC plastisol.

Description:
PVC- BASED, LAYERED FLOOR COVERING

Technical field

The invention relates to PVC-based, layered floor coverings, and methods for the production of such floor coverings.

Prior art

PVC-based, layered floor coverings are already generally known. The floor coverings known to date have a number of possible drawbacks. As is generally the case, the sound damping for continuous noise is not adequate, the floor coverings may possibly show a lasting imprint after point loading (for example by table or chair legs), and floor coverings that are not fully glued to the substrate tend to wrinkle if an object is slid over their surface. All of this is particularly the case if the floor covering is configured as a floor covering that is wall-to-wall, soft, and capable of being rolled up. These floor coverings should also remain flat after being unrolled, which is not always the case.

Summary of the invention

An object of the invention is to provide a PVC-based, layered floor covering that is capable of achieving a good compromise with respect to the above-mentioned drawbacks.

In accordance with a first aspect, a PVC-based, layered floor covering is provided, comprising the following successive layers:

a. a first PVC layer;

b. a layer of a first PVC permeated textile product;

c. a second PVC layer;

d. a layer of a second PVC permeated textile product;

e. a decorative layer comprising a polymer layer;

f. a wear layer comprising a transparent polymer layer;

wherein the first PVC layer has a thickness of more than 2.0 mm, consists of foamed PVC and provides the underside of the floor covering. Preferably, the thickness of the first layer is selected in the range of 2.0 mm to 3.5 mm, more preferably between 2.3 mm and 3.0 mm, for example between 2.4 mm and 2.6 mm .

In accordance with embodiments, the density of the first PVC layer can be in the range of 0.25 to 1.00 g/cm 3 . The PVC of the first PVC layer preferably has a density of 0.30 to 0.80 g/cm 3 , such as 0.30 to 0.50 g/cm 3 . The PVC of the first PVC layer is foamed. A foamed layer refers to a layer that has hollow cavities, preferably in an amount such that the density of the material is reduced by at least 10%, and preferably even at least 25%, with respect to the weight of an equal volume of thermoplastic material without hollow cavities. Preferably, this is so-called closed cell foam. A non-foamed layer refers to a layer without hollow cavities, or at least, however, with a maximum proportion of hollow cavities such that the density of the material is not reduced, or is reduced by not more than 10%, and preferably even by not more than 2%.

The PVC can be chemically or mechanically foamed.

In accordance with a first possibility, the foamed layer is obtained at least by means of a mechanical foaming process. This means that cavities are formed in the layer in question by pressing out the thermoplastic material and replacing it with a gas (such as air), often under the influence of a mechanical action or by blowing in of a gas (such as air) under pressure.

In accordance with a second possibility, the foamed layer is obtained at least by means of a chemical foaming process. This means that cavities are formed in the layer in question by means of a gaseous reaction product. For example, azodicarbonamide can be used. On heating, this substance releases nitrogen gas that remains present in the foamed layer in the form of bubbles.

In accordance with a third possibility, the foamed layer is obtained at least by means of fillers, wherein these fillers themselves comprise one or more cavities. For example, one can make use of the expanded state of the above-mentioned microspheres. More particularly, one can make use of the microspheres known from WO 2013/178561. Or it can be obtained by using expanded granules in a PVC-based layer. In accordance with embodiments, the PVC of the first PVC layer can be a soft PVC. Preferably, the soft PVC of the first PVC layer comprises plasticizers, in an amount of 15 to 100 phr, and preferably in an amount of 30 to 100 phr, for example 50 to 80 phr. “Phr” stands for parts by weight of plasticizer per hundred parts by weight of PVC. The plasticizers can include, inter alia, esters of carboxylic acids (for example esters of ortho- or terephthalic acid, trimellitic acid, benzoic acid and adipic acid), for example diisononylphthalate (DINP), dioctyl terephthalate (DOTP), di-isononyl-1 , 2-cyclohexane dicarboxylate (DINCH), esters of phosphoric acid, for example triaryl or trialkylaryl phosphates, for example tricresyl phosphate, chlorinated or non-chlorinated hydrocarbons, ethers, polyesters, polyglycols, sulfonamides, or combinations thereof.

The PVC of the first PVC layer possibly also comprises fillers, such as glass fibers, calcium hydroxide (slaked lime), calcium carbonate and calcium hydrogencarbonate, and/or CaMg(CC>3)2, talc, or also lightweight fillers such as hollow microspheres (Expancel). The PVC formulation of this PVC layer can comprise fillers to between 10 and 50 wt%, preferably between 15 and 45 wt%, for example between 20 and 45 wt%. The above-mentioned percent by weight (wt%) is expressed as the weight of the filler with respect to the weight of the entire polymer formulation, in this case PVC, in which the filler is contained.

Furthermore, this PVC can comprise additives such as pigments and dyes, preservatives, antifungal agents, thermal stabilizers, UV stabilizers, blowing agents, viscosity regulators, and the like.

In accordance with embodiments, the PVC of the second PVC layer can be a soft PVC. Preferably, the soft PVC of the second PVC layer comprises plasticizers, in an amount of 15 to 100 phr, and preferably in an amount of 30 to 100 phr, for example 30 to 60 phr. “Phr” stands for parts by weight of plasticizer per hundred parts by weight of PVC. The plasticizers can include, inter alia, esters of carboxylic acids (for example esters of ortho- or terephthalic acid, trimellitic acid, benzoic acid and adipic acid), for example diisononylphthalate (DINP), dioctyl terephthalate (DOTP), di-isononyl-1 , 2-cyclohexane dicarboxylate (DINCH), esters of phosphoric acid, for example triaryl or trialkylaryl phosphates, for example tricresyl phosphate, chlorinated or non-chlorinated hydrocarbons, ethers, polyesters, polyglycols, sulfonamides, or combinations thereof. The PVC of the second PVC layer possibly also comprises fillers, such as glass fibers, calcium hydroxide (slaked lime), calcium carbonate and calcium hydrogencarbonate, and/or CaMg(CC>3)2, talc, or also lightweight fillers such as hollow microspheres (Expancel). The PVC formulation of this PVC layer can comprise fillers to between 10 and 60 wt%, preferably between 15 and 45 wt%, for example between 15 and 35 wt%. The above-mentioned percent by weight (wt%) is expressed as the weight of the filler with respect to the weight of the entire polymer formulation, in this case PVC, in which the filler is contained.

Furthermore, this PVC can comprise additives such as pigments and dyes, preservatives, antifungal agents, thermal stabilizers, UV stabilizers, blowing agents, viscosity regulators, and the like.

In accordance with certain embodiments, the PVC of the second PVC layer can be unfoamed. In accordance with other embodiments, the PVC of the second PVC layer can be foamed.

The PVC of the second PVC layer preferably has a density of 0.30 to 0.80 g/cm 3 , such as 0.30 to 0.50 g/cm 3 . The PVC of the second PVC layer can be foamed in accordance with the methods described above. The foamed PVC of the second PVC layer can be foamed in a similar, identical or different manner compared to the foamed PVC of the first PVC layer.

The PVC of the second PVC layer can also be unfoamed, and then has a density of for example more than 1 g/cm 3 , for example between 1.2 and 1.9 g/cm 3 , such as 1.3 to 1.6 g/cm 3 .

Preferably, the thickness of the second layer is selected in the range of 0.2 mm to 2 mm, more preferably between 0.3 mm and 1.2 mm, for example between 0.4 mm and 0.8 mm .

Between this first PVC layer and this second PVC layer, a layer of a first PVC permeated textile product is provided. This first textile product is preferably a textile product comprising glass fibers, such as a glass fiber nonwoven or a glass fiber woven. Preferably, a glass fiber nonwoven is used, which preferably can have a surface weight of between 30 and 60 g/m 2 and a thickness of between 0.20 and 0.45 mm, for example between 0.25 and 0.45mm.

In accordance with embodiments, the first textile product can be partially impregnated with the PVC of the second PVC layer and partially impregnated with the PVC of the first PVC layer, so that first textile product is permeated with PVC.

In accordance with embodiments, the first textile product can be completely permeated, and therefore permeated, with the PVC of the first PVC layer.

In accordance with embodiments, the first textile product can be completely permeated, and therefore permeated, with the PVC of the second PVC layer.

This permeation can be achieved during the production process for producing a floor covering in accordance with the second aspect of the invention. In accordance with alternative embodiments, the first textile product can be permeated with a PVC that is either identical to the PVC of the first PVC layer, identical to the PVC of the second PVC layer, or completely different from the PVCs used for the production of the first and second PVC layer.

The first PVC permeated textile product therefore comes into contact with the second PVC layer on a first side of the second PVC layer. Optionally, this first textile product is permeated by this second PVC layer.

On the second, opposite side of the second PVC layer, this second PVC layer is brought into contact with a second textile product, which is a part of a layer of a second PVC permeated textile product.

This second textile product is preferably a textile product comprising glass fibers such as a glass fiber nonwoven or a glass fiber woven. This second textile product can, but does not have to be, the same product as the first textile product.

Preferably, a glass fiber nonwoven is used for this second textile product that preferably can have a surface weight of between 30 and 60 g/m 2 and a thickness of between 0.20 and 0.45 mm, for example between 0.25 and 0.45 mm. In accordance with embodiments, the second textile product can be permeated with the PVC that is either identical to the PVC of the first PVC layer, identical to the PVC of the second PVC layer, or completely different from the PVCs used for the production of the first and second PVC layer.

In accordance with embodiments, the second textile product can be permeated with the PVC that is different from the PVC of the first and the second PVC layer.

Preferably, a PVC is used for the permeation of the second textile product, more preferably a soft PVC. Preferably, a PVC with a density of for example more than 1 g/cm 3 is used, for example between 1.2 and 1.9 g/cm 3 , such as 1.3 to 1.6 g/cm 3 .

Preferably, this soft PVC comprises plasticizers, in an amount of 15 to 100 phr, and preferably in an amount of 30 to 100 phr, for example 50 to 80 phr.

Preferably, the thickness of the layer of the second with PVC permeated textile product is between 0.3 and 0.4mm.

The second PVC permeated textile product therefore comes into contact with the second PVC layer on a first side of the PVC permeated textile product. On the second side of the second PVC permeated textile product, this second PVC permeated textile product is brought into contact with a decorative layer.

This decorative layer comprises a polymer layer, typically again PVC, which has the purpose of determining the final outer appearance of the floor covering. A decorative pattern or motif can be applied to this polymer layer, for example with ink, such as waterproof inks. Optionally, this pattern or motif is not more than one uniform color other than the color of the polymer used. In an alternative form, the polymer is dyed in the mass.

Preferably, a PVC is used for the provision of the decorative layer, more preferably soft PVC. Preferably, a PVC with a density of for example more than 1 g/cm 3 is used, for example between 1.2 and 1.9 g/cm 3 , such as 1.3 to 1.6 g/cm 3 . Preferably, this soft PVC comprises plasticizers, in an amount of 15 to 100 phr, and preferably in an amount of 30 to 100 phr, for example 50 to 80 phr. In order to make the layer opaque or white, this PVC layer preferably comprises Ti02, preferably larger amounts of Ti02.

In accordance with embodiments, the polymer of the decorative layer can be PVC.

In accordance with embodiments, the polymer of the decorative layer can be foamed PVC.

In accordance with embodiments, the polymer of the decorative layer can be unfoamed PVC.

Preferably, the thickness of the decorative layer is between the 0.1 and 0.6 mm, for example between 0.15 and 0.25 mm.

On the side opposite the side of the decorative layer that comes into contact with the second textile product permeated with PVC, a wear layer is provided.

This wear layer comprises a transparent polymer layer, again preferably transparent PVC.

In accordance with embodiments, the polymer of the wear layer can be PVC.

Preferably, a PVC with a density of for example more than 1 g/cm 3 is used, for example between 1.1 and 1.6 g/cm 3 , such as 1.15 to 1.35 g/cm 3 .

Preferably, this soft PVC comprises plasticizers, in an amount of 15 to 100 phr, and preferably in an amount of 30 to 100 phr, for example 50 to 80 phr. Preferably, this PVC layer is not filled, and therefore comprises no fillers.

Preferably, the thickness of the wear layer is between 0.1 and 0.7 mm, for example between 0.35 and 0.55.

Possibly, on the wear layer, on the side that does not come into contact with the decorative layer, another lacquer layer can be applied. This lacquer is preferably a polyurethane (PU) lacquer, with a surface weight of preferably between 10 and 30 g/m 2 , and a thickness of between 10 and 30 pm.

The floor covering in accordance with this first aspect of the invention has a number of advantages. The floor covering can be rolled up, i.e. can be provided on a roll, for example a roll 2 to 4 meters in width and for example up to 20 or 30 meters in length, but behaves as a flat surface once it is unrolled onto a flat substrate. It remains dimensionally stable and shows little or no wrinkle formation when objects, for example furniture, are slid over the surface, and this without gluing the floor covering to the substrate. The floor covering also provides an improvement in contact sound insulation ALw of 20 dB: this is the sound damping for continuous sound. The determination of improvement in the contact sound insulation ALw is measured in accordance with the standards NF EN ISO 10140-1 (2013), NF EN ISO 10140-3 (2013), NF EN ISO 10140- 4 (2013) and NF EN ISO 10140-5 (2013), supplemented by standard NF EN ISO 717/2 (2013) and annexes. The resistance to point load is also adequate.

In accordance with embodiments, the floor covering can be between 2 and 4 meters wide and 20 to 30 meter long. The floor covering can be provided in rolled-up form.

In accordance with a second aspect of the invention, a method is provided for producing a floor covering. The method for producing a floor covering in accordance with the second aspect comprising the following successive steps:

a. the provision of a first PVC permeated textile product that corresponds to the second PVC permeated textile product of the floor covering in accordance with the first aspect of the invention;

b. the application, to a first side of the permeated textile product, of the polymer layer of the decorative layer;

c. the application, to the free side of the polymer layer of the decorative layer, of the polymer layer of the wear layer,

d. the application, to the second side of the permeated textile product, of a PVC layer that corresponds to the second PVC layer of the floor covering in accordance with the first aspect of the invention;

e. the application of a further textile product to this PVC layer, which textile product corresponds to the textile product of the first PVC permeated textile product of the floor covering in accordance with the first aspect of the invention;

f. the application to the further textile product of a layer of foamable or foamed PVC that is to provide the first PVC layer of the floor covering in accordance with the first aspect of the invention, which foamable or foamed PVC is to have a thickness of more than 2 mm in a foamed state.

In accordance with certain embodiments, the provision of a first PVC permeated textile product can comprise the following steps:

a.i.- the provision of a textile product;

a.ii.- the permeation of this textile product with a first PVC plastisol; a.iii.- the pregelling of the first PVC plastisol.

In accordance with certain embodiments, the application to the second side of the permeated textile product of a PVC can comprise the following steps:

d.i.- the application, to the second side of the permeated textile product, of a PVC plastisol;

d.ii.- the pregelling of this PVC plastisol.

In accordance with certain embodiments, step e can take place before step d.ii, wherein the PVC penetrates into the further textile product in order to permeate the further textile product.

In accordance with certain embodiments, the application to the further textile product of a layer of foamable or foamed PVC can comprise the following steps:

f.i.- the application to the further textile product of a layer of foamable or foamed PVC plastisol;

f.ii.- optionally, the pregelling of this PVC plastisol.

In accordance with certain embodiments, the method can comprise the following steps:

a. the provision of a first PVC material permeated textile product that corresponds to the second PVC permeated textile product of the floor covering in accordance with the first aspect of the invention, comprising i. the provision of a textile product;

ii. the impregnation of this textile product with a PVC plastisol; iii. the pregelling of the first PVC plastisol;

b. the application, to a first side of the impregnated textile product, of the polymer layer of the decorative layer;

c. the application, to the free side of the polymer layer of the decorative layer, of the polymer layer of the wear layer,

d. the application of a PVC layer that corresponds to the second PVC layer of the floor covering in accordance with the first aspect of the invention comprising

i. the application, to the second side of the impregnated textile product, of a PVC plastisol layer;

ii. the pregelling of this PVC plastisol;

e. the application of a further textile product to this PVC layer, which textile product corresponds to the textile product of the first PVC permeated textile product of the floor covering in accordance with the first aspect of the invention;

f. the application to the further textile product of a layer of foamable or foamed PVC that is to provide the first PVC layer of the floor covering in accordance with the first aspect of the invention, which foamable or foamed PVC is to have a thickness of more than 2 mm in a foamed state, comprising

i. the application to the further textile product of a layer of a foamable PVC plastisol, which is to have a thickness of more than 2 mm in a foamed and gelled state;

ii. optionally, the pregelling of this PVC plastisol;

g. the gelling of all PVC plastisols.

As a result of the second PVC plastisol applied in step d.i, after gelling, this plastisol brings about the second PVC layer of the floor covering in accordance with the first aspect of the invention. As a result of the third PVC plastisol applied in step f.i, after gelling, this plastisol brings about the first PVC layer of the floor covering in accordance with the first aspect of the invention.

In accordance with certain embodiments, after step g, a lacquer layer can be applied to the wear layer. In accordance with certain embodiments, step e can take place before d.ii, and wherein the PVC plastisol of step d.i penetrates into the further textile product in order to permeate the further textile product.

In accordance with certain embodiments, during step f, the PVC plastisol can penetrate into the further textile product in order to permeate the textile product.

The pregelling takes place via a drying step, wherein the PVC plastisol is partially dried and is dried such that it is suitable for receiving the following layer.

Step a provides the PVC permeated second textile product of the floor covering in accordance with the first aspect of the invention. In the case of steps a.i to a.iii, the steps can take place by applying the PVC plastisol to one or both sides of the textile product. Using a doctor blade, the plastisol can be pressed into the textile product.

The polymer applied in step b provides the floor covering in accordance with the first aspect of the invention with a decorative layer.

In accordance with certain embodiments, during step b, a decorative pattern can be applied.

The polymer applied in step c provides the floor covering in accordance with the first aspect of the invention with a wear layer.

In accordance with certain embodiments, in step b, the polymer of the decorative layer can be a PVC plastisol and wherein step b comprises the pregelling of this PVC plastisol.

In accordance with certain embodiments, in step c, the polymer of the decorative layer can be a PVC plastisol and wherein step c comprises the pregelling of this PVC plastisol.

In accordance with alternative embodiments, the textile product impregnated with a first PVC material is provided by extrusion of the PVC material on or around the textile product. In accordance with alternative embodiments, the decorative layer and/or the wear layer can be applied by thermal lamination to the underlying layer, or the layer can be provided by extrusion of the corresponding PVC material onto the underlying layer.

In accordance with still further embodiments, the layer of a second PVC can be provided by thermally laminating one or more layers of the corresponding PVC onto the underlying layer, or the layer can be provided via extrusion of the corresponding PVC material onto the underlying layer.

In accordance with still further embodiments, the layer of a third, foamable or foamed PVC can be provided by thermally laminating one or more layers of the corresponding PVC onto the underlying layer, or the layer can be provided via extrusion of the corresponding PVC material onto the underlying layer.

The method in accordance with a second aspect of the invention can be used for producing a floor covering in accordance with the first aspect of the invention.

The independent and dependent claims describe specific and preferred features of the embodiments of the invention. Features of the dependent claims can be combined with features of the independent and dependent claims, and this in any suitable manner that would be clear to a person skilled in the art.

The above-mentioned and other features, characteristics and advantages of the present invention are to be clarified by means of the following examples of embodiments, optionally in combination with the drawings.

The description of these examples of embodiments is given as a clarification, without intending to limit the scope of the invention. The reference numbers in the following description refer to the drawings. The same reference numbers in any different figures refer to identical or similar elements.

Brief description of the figures

In order to better demonstrate the features of the invention, several preferred embodiments are described below as examples that are not in any way limitative, with reference to the accompanying drawings, wherein: • Fig. 1 is a schematic representation of a production process in accordance with the invention.

• Fig. 2 is a schematic representation of a cross-section of a floor covering in accordance with the invention.

Description of examples of embodiments

The present invention is described below by means of specific embodiments.

It is to be noted that the term "comprising", as used in the claims, must not be interpreted in a limitative sense as being limited to the following elements, features and/or steps. The term "comprising" does not exclude the presence of other elements, features or steps.

The scope of the term "an object comprising the elements A and B" is therefore not limited to an object that only comprises the elements A and B. The scope of the term "a method comprising the steps A and B" is not limited to a method that only comprises the steps A and B.

In the sense of the present invention, these terms simply mean that the relevant elements or steps for the invention are the elements or steps A and B.

In the following specification, reference is made to "an embodiment” or "the embodiment". Such a reference means that a specific element or feature described by means of this embodiment is contained in at least this one embodiment.

However, the presence of the terms "in an embodiment" or "in embodiments" at various places in this description does not necessarily refer to the same embodiment, although it may refer to the same embodiment.

Furthermore, the characteristics or the features can be combined into one or more embodiments in any suitable manner that would be clear to the person skilled in the art.

Fig. 1 schematically shows a production method for producing a floor covering in accordance with the invention. A first textile product, for example a glass fiber nonwoven 1 10, is unrolled and supplied to a first station 120 for the application of a first PVC plastisol 122. By means of a doctor blade 124, the plastisol is pressed into the nonwoven, so that a textile product 130 permeated with PVC plastisol is obtained. The plastisol 122 is pregelled at a first drying station 140.

On a first side of the permeated textile product 130, a PVC plastisol 152 is applied via a second station 150 in order to provide a decorative layer. Again with a doctor blade 154, the thickness of this layer of plastisol is set. The plastisol 152 is pregelled at a second drying station 160. After the application of a decorative pattern by means of a printing station 170, a transparent PVC plastisol 182 is then applied via a third station 180 in order to provide a wear layer. Again with a doctor blade 184, the thickness of this layer of plastisol is set. The plastisol 182 is pregelled at a third drying station 190. The printing station can be a digital printer, but can just as well be a rotogravure cylinder for rotary printing. In the case of rotary printing, it is possible that the intermediate product is again turned before and after the printer in order to position the printing roll under the product to be printed.

At a turning station 200, the intermediate product is turned so that the second side of the textile product 130 permeated with plastisol is turned upward. On this side of the textile product 130 permeated with plastisol, a further PVC plastisol layer 212 is then applied at a station 210. Again with a doctor blade 214, the thickness of this PVC plastisol layer is set. This plastisol can optionally be a foamable plastisol.

A further textile product 11 1 is brought into contact with the wet PVC plastisol 212, and by means of a light pressure exerted for example by the roll 220, the PVC plastisol 212 partially impregnates the further textile product 1 11 , for example a glass fiber nonwoven.

At drying station 230, the PVC plastisol 212 is pregelled.

Subsequently, a layer of a foamable PVC plastisol 242 is applied at station 240, wherein again the doctor blade 244 is to determine the thickness of the applied layer. Subsequently, the plastisol 242 is first pregelled in an oven 250, and all of the layers of plastisol are then to be gelled in this oven. During this passage through the oven 250, all of the pregelled plastisols are to be further gelled, and the foamable plastisol or plastisols are to foam. The pregelling of plastisol 242 and gelling of all of the layers of plastisol can also be carried out in one step and in one oven.

Finally, the product obtained is turned at turning station 260, after which a UV-hardened PU lacquer layer is applied by means of a lick roller 270 and is hardened with UV at station 280.

The floor covering 300 thus obtained can be rolled up at rolling-up station 290.

The product obtained 300 has a cross section as schematically shown in Fig. 2. As the representation is schematic, the thicknesses as shown are not metrically representative.

The PVC-based, layered floor covering comprises successive layers, specifically:

a. a first PVC layer 1240 that is obtained at station 240;

b. A layer 1220 of a first textile product permeated with PVC, wherein the textile product is the textile product 1 1 1 that is permeated with the plastisol 212;

c. a second layer 1210 of PVC derived from PVC plastisol 212; d. a layer of a textile product permeated with PVC 1 130, which comprises the textile product 110 that is permeated with PVC plastisol 122;

e. a decorative layer 1 150 comprising a polymer layer derived from the PVC plastisol 152 and the decorative pattern;

f. a wear layer 1180 comprising a transparent polymer layer derived from the PVC plastisol 182;

g. the PU lacquer layer 1270.

The following layer thicknesses are applicable:

The PVC plastisol of PVC layer 1240 is a soft PVC with a density of 0.3 to 0.4 g/cm 3 . It comprises approximately 30 wt% of filler and 60 phr of plasticizer.

PVC plastisol of PVC layer 1210 is a soft PVC with a density of 1.3 to 1.4 g/cm 3 . It comprises approximately 20 wt% of filler and 40 phr of plasticizer.

The PVC of the PVC permeated textile product 1 130 is a soft PVC with a density of 1.5 to 1.6 g/cm 3 . It comprises approximately 40 wt% of filler and 60 phr of plasticizer.

The PVC of the decorative layer comprises soft PVC with a density of 1.5 to 1.6 g/cm 3 . It comprises approximately 40 wt% of filler and 60 phr of plasticizer.

The PVC of the wear layer comprises soft PVC with a density of 1.2 to 1.3 g/cm 3 . It comprises no filler and comprises 40 phr of plasticizer.

All of the PVCs are obtained by emulsion or (micro)suspension polymerization and have a K value of between 50 and 90.

Textile product 110 is a glass fiber nonwoven with a surface weight of 35 g/m 2 and a thickness of approximately 0.3 mm.

Textile product 11 1 is a glass fiber nonwoven with a surface weight of 50 g/m 2 and a thickness of approximately 0.4 mm.

PU lacquer is applied in an amount of 20 g/m 2 and a thickness of 20 pm. A 100% solid UV lacquer is used.

The ALw is 20 dB: this value represents the improvement in contact sound insulation by means of using the product.

The product, like all products in accordance with the invention, has particularly favorable values in terms of expansion under the influence of temperature. The above-mentioned product was subjected to a dilation test in accordance with EN ISO 23999. A product identical to the above-mentioned product but with a glass fiber reinforcement was subjected to the test in a similar manner. For both the production direction and the direction perpendicular to the production direction, it was found that by using two glass fiber reinforcements, a reduction in expansion by 50% was obtained. It is clear that, although the embodiments and/or the materials for providing embodiments in accordance with the present invention are discussed, various amendments or modifications can be applied without deviating from the scope of this operating range and/or the spirit of this invention. The present invention is by no means limited to the embodiments described above, but can be realized in accordance with different variants without departing from the scope of the present invention.