EP4707460A2

EP4707460A2 - Floor covering product

Info

Publication number: EP4707460A2
Application number: EP25193314.9A
Authority: EP
Inventors: Justine Huysman; Jeroom Van Lindt
Original assignee: Unilin BV
Current assignee: Unilin BV
Priority date: 2024-08-27
Filing date: 2025-08-01
Publication date: 2026-03-11

Abstract

The floor covering product (10, 20) comprises a wear layer (17). The bottom of the floor covering product is formed by a polyurethane layer (18, 28) over at least 50% of its surface - and preferably over its whole surface.

Description

The invention relates to a floor covering product, for example a floor tile. The invention more particularly relates to floor covering products having a resilient wear layer, such as for example carpets, carpet tiles and vinyl tiles.
Carpet tiles and vinyl tiles are known.
WO2021/141947A1 describes a carpet tile having a low weight and a process for producing such a carpet tile. The carpet tile comprises pile yarns tufted through a primary backing, a polyolefin coating having low viscosity applied to the backside of the primary backing, a reinforcing open textile cloth and an extruded polyolefin layer.
It is the object of the invention to solve problems of state-of-the-art carpet tiles.
More particularly, it is an object to provide carpet tiles which may be installed more easily and more sustainably.
The invention relates to a floor covering product. The floor covering product comprises a wear layer. The floor covering product is characterized in that the bottom of the floor covering product is formed by a polyurethane layer over at least 50% of its surface - and preferably over its whole surface.
Floor covering products such as carpet tiles and so-called loose-lay vinyl tiles are traditionally installed by applying a pressure-sensitive adhesive (PSA) to the floor. After one day of drying this pressure-sensitive adhesive, the floor covering products, such as carpet tiles and loose-lay vinyl tiles, may be laid in this pressure-sensitive adhesive. This is a way that ensures a stable placement of the floor covering products and still allows easy removal of the floor covering products.
The inventors have noticed that, with floor covering products according to the invention, the polyurethane layer forming the bottom of the floor covering product obviates the need for applying a pressure-sensitive adhesive (PSA) to the floor. The floor covering product may simply be laid on the floor, allowing the same stability of installation of the floor covering to be achieved. The presence of the polyurethane layer forming the bottom of the floor covering product has been found to successfully replace the function of a pressure-sensitive adhesive layer applied to the floor on which the floor covering is laid.
Thus, the floor covering according to the invention may be installed more quickly. The release of volatile organic compounds (VOC's) when drying the pressure-sensitive adhesive is avoided, since no pressure-sensitive adhesive needs to be used when installing the floor covering. This allows the floor covering products according to the invention to be installed in a more sustainable and environmentally friendly manner.
Preferably, the polyurethane layer is a polyurethane foam layer. This may be either a closed-cell polyurethane foam layer or an open-cell polyurethane foam layer.
The use of a polyurethane foam layer was found to offer a very good stability of the installed floor covering.
The polyurethane layer is preferably a polyether polyurethane layer or a polyester polyurethane layer.
The use of a polyether polyurethane layer is particularly advantageous, since the use of a polyester polyurethane layer ensures a very good and stable installation of the floor covering product for a long time, also in spaces with sharp variations in temperature.
Preferably, the polyurethane layer has at least a mass of 50 grams per square meter, and more preferably of at least 75 grams per square meter. Preferably, the polyurethane layer has a mass of less than 200 grams per square meter, and more preferably of less than 150 grams per square meter.
Preferably, the polyurethane layer has a mass of 80 grams per square meter.
A preferred embodiment of the floor covering product comprises a felt layer, the polyurethane layer contacting the felt layer.
These embodiments ensure an even easier installation, because the felt layer may smooth out irregularities in the floor onto which the floor covering product is laid.
Preferably, the felt layer is a polyester felt layer, or the felt layer comprises at least polyester fibers. Preferably, it may consist of at least 50 weight percent of polyester fibers.
The felt layer is preferably a needle felt or a hydroentangled felt. The use of a needle felt is preferred due to its high volume per unit of mass.
The felt layer preferably has a mass of at least 100 grams per square meter, and more preferably of at least 150 grams per square meter, and still more preferably of at least 200 grams per square meter. Such felt layers provide an even better performance with regard to the sustainable installation of the floor covering products according to the invention.
A preferred floor covering product is characterized in that the wear layer is a resilient wear layer.
The floor covering product may be a carpet or a carpet tile. Preferably, the carpet or the carpet tile has a mass of more than 3.5 kg/m².
Carpet tiles according to the invention are preferably square or elongated rectangular.
The carpet tiles may, for example, be elongated rectangular with dimensions of 250 millimeters to 1000 millimeters.
The carpet tiles may, for example, be square with dimensions of 500 millimeters to 500 millimeters.
Preferably, the wear layer comprises decorative yarns or the wear layer is formed by decorative yarns. Preferably, the decorative yarns are pile yarns. The wear layer may therefore also be of the cut-pile type or of the loop-pile type, or comprise combinations of loop piles and cut piles.
The pile yarns may, for example, be polyamide pile yarns, polypropylene pile yarns or polyester pile yarns.
The wear layer may comprise a primary textile backing, the decorative yarns (for example the pile yarns) being attached to or in the primary textile backing.
The primary textile backing may be or comprise a textile nonwoven or woven cloth.
The primary textile backing may, for example, be a polyester nonwoven, a polypropylene nonwoven, or a polyester/polypropylene nonwoven.
The wear layer may be tufted or woven.
The wear layer may also be a bonded carpet, wherein pile yarns are adhered in an adhesive layer to the wear layer, the adhesive layer being applied to the same side of the primary textile backing as the pile yarns themselves. With such a bonded carpet, the pile yarns do not go through the primary textile backing.
The wear layer may comprise a felt on the surface of the floor covering. This felt may preferably be a needle felt. The felt may be a polyester felt or a polypropylene felt, or a felt from a mixture comprising at least polyester fibers and/or polypropylene fibers.
The floor covering product according to the invention preferably comprises a polymer coating layer provided on the underside of and contacting the wear layer. Such a polymer coating layer is also known as a precoat.
In embodiments wherein the floor covering product comprises a primary textile backing and pile yarns passing through the primary textile backing, the coating layer serves to better anchor these pile yarns. Such a polymer coating layer is, for example, used with tufted carpets and with tufted carpet tiles.
The polymer coating layer may preferably be selected from an acrylate, a styrene acrylate, a styrene butadiene copolymer, an ethylene vinyl acetate copolymer, a latex, a thermoplastic polymer, or combinations thereof. The polymer coating layer preferably comprises inorganic fillers, for example CaCO₃.
The polymer coating layer preferably has a weight of between 1600 and 2000 grams per square meter.
The floor covering product according to the invention preferably comprises a secondary backing. This secondary backing is located under the coating layer, and under the polymer coating layer if this is present.
Preferably, the secondary backing is or comprises a thermoplastic secondary backing. The thermoplastic secondary backing may be or comprise a bitumen layer, preferably filled with inorganic material, such as CaCO₃.
Preferably, the secondary backing is or comprises a thermoplastic polymer layer, for example a polyolefin layer, preferably filled with inorganic material, such as CaCO₃.
The secondary backing preferably has a weight of between 1800 and 2700 grams per square meter.
The secondary backing may comprise a reinforcement cloth. An example of a reinforcement cloth which may be used in the framework of the invention is a polyester nonwoven or a glass nonwoven.
An open glass cloth or a glass nonwoven may be pressed on the underside in or against the secondary backing (for example in or against the bitumen layer or other thermoplastic polymer layer). As an open glass cloth, a polymer-bound laid fabric of glass yarns, may be used. The polymer with which the laid fabric is bound, may be selected from polyvinyl alcohol, polyvinyl chloride, acrylate, styrene butadiene copolymer, or a thermoplastic binder.
In a preferred embodiment of the invention, the floor covering product comprises a vinyl wear layer. Preferably, this vinyl wear layer is formed by a vinyl film, more preferably by a polyvinyl chloride film. This vinyl film preferably has a thickness of between 0.1 and 0.7 millimeters.
Optionally, this vinyl film comprises a lacquer layer. Examples of lacquer layers which may be used in the invention are acrylate lacquer layers and polyurethane lacquer layers. These lacquer layers have the object to improve the scratch resistance of the floor covering product.
Preferably, the wear layer is transparent. Preferably, the wear layer is colorless.
The vinyl film forming the vinyl layer may be provided with a texture pressed in the surface of the vinyl film.
Preferably, the floor covering product comprises a decoratively printed film under the vinyl wear layer. This decoratively printed film may be a decoratively printed vinyl film, for example a decoratively printed polyvinyl chloride film.
The decoratively printed film may be a foamed film (for example having a thickness of 0.2 millimeters) or be a compact film (for example having a thickness of 0.07 millimeters). A compact film is intended to mean a film which has not been foamed.
The floor covering product may comprise multiple vinyl layers (for example multiple polyvinyl chloride layers), preferably these multiple vinyl layers are filled with inorganic filler, for example CaCO₃.
Preferably, floor covering products according to the invention comprising a vinyl wear layer comprise one or more reinforcement cloths, more preferably each of the one or more reinforcement cloths is positioned between two of the multiple vinyl layers.
Floor covering products according to the invention comprising a vinyl wear layer preferably comprise one or more reinforcement cloths. These one or more reinforcement cloths may be glass clothe, for example polymer-bound laid glass fabrics or nonwovens from glass fiber. With polymer-bound laid glass fabrics, the polymer to which the glass yarns of the laid fabric are bound, may be selected from polyvinyl alcohol, polyvinyl chloride, acrylate, styrene butadiene copolymer, or a thermoplastic binder. Nonwovens from glass fiber may be polymer-bound nonwovens from glass fiber, for example polymer-bound nonwovens from glass fiber bound with an acrylate binder. The reinforcement cloths may be coated with polyvinyl chloride to ensure adhesion of the reinforcement cloths in the floor covering product.
According to a preferred embodiment of the invention, the floor covering product comprises a vinyl wear tile. This vinyl tile may be a polyvinyl chloride floor tile. The vinyl tile may, for example, be square, or elongated rectangular, or hexagonal.
With a view to better demonstrating the characteristics of the invention, the following, as an example without any restrictive character, describes some preferred embodiments, with reference to the appended drawings, in which:

Figure 1 shows a carpet tile as an example of a floor covering product according to the invention.
Figure 2 shows a vinyl tile as an example of a floor covering product according to the invention.
Figure 3 shows a floor covering with floor covering products according to the invention;

Figure 1 shows a carpet tile 10 as an example of a floor covering product according to the invention. The carpet tile 10 comprises a wear layer 17. The floor tile may be square (for example having a dimension of 500 millimeters to 500 millimeters) or elongated rectangular (for example having dimensions of 250 millimeters to 1000 millimeters),
The bottom of the carpet tile 10 is formed by a polyurethane layer 18 over the whole surface thereof, more specifically, in the example, by a polyurethane foam layer comprising closed cells.
The polyurethane layer 18 has a mass of 85 grams per square meter and is adhered to a polyester felt layer 16 of 150 grams per square meter, In the example, this polyester felt layer 16 is a needle felt.
In the example of the carpet tile 10 of Figure 1, the wear layer 17 is a tufted cloth. This wear layer 17 comprises pile yarns 11 - as decorative yarns - tufted through a primary textile backing 12.
On the underside of the wear layer 17, a polymer coating layer 13 is provided. This contacts the primary textile backing 12 and serves to ensure the anchoring of the pile yarns 11 in the primary textile backing 12. This polymer coating layer 13 may, for example, be a styrene acrylate copolymer or a styrene butadiene copolymer coating layer, preferably filled with an inorganic filler, such as CaCO₃.
The carpet tile also comprises a secondary backing 14. In this example, the secondary backing 14 is a bitumen layer comprising inorganic filler, such as CaCO₃. Alternatively, the secondary backing may be formed by a polyolefin layer filled with inorganic filler, such as CaCO₃.
The polyester felt layer 16 already mentioned comprising the polyurethane layer 18 on the underside, was pressed against the secondary backing 14 when it was applied when hot (and therefore in plastic condition).
Figure 2 shows a vinyl tile 20 as an example of a floor covering product according to the invention. The vinyl tile 20 comprises a wear layer 17. The wear layer 17 is a resilient wear layer. This resilient wear layer comprises a colorless, transparent polyvinyl chloride film 21, on which a lacquer layer is located. This lacquer layer may be a polyurethane lacquer layer or an acrylate lacquer layer. The wear layer 17 has, for example, a thickness of between 0.1 millimeters and 0.7 millimeters, for example a thickness of 0.37 millimeters.
Under the colorless, transparent polyvinyl chloride film 21, the vinyl tile 20 comprises a decoratively printed polyvinyl chloride film 22 providing the visible décor of the vinyl tile 20, optionally combined with a texture pressed in the colorless, transparent polyvinyl chloride film 21. The decoratively printed polyvinyl chloride film 22 may be a foamed film, for example with a thickness of 0.2 millimeters, or be a compact - that is, nonfoamed - film, for example with a thickness of 0.07 millimeters.
The vinyl tile 20 further comprises a core layer 23 from polyvinyl chloride filled with inorganic filler, for example with CaCO₃. The vinyl tile 20 also comprises two glass cloths 24 as reinforcement cloths, on the underside and the top side of core layer 23 from polyvinyl chloride filled with inorganic filler, respectively.
Under the lower glass cloth 24, the vinyl tile 20 comprises a foamed polyvinyl layer 25 comprising CaCO₃ as an inorganic filler. This foamed polyvinyl layer has, for example, a thickness of 1 millimeter.
The two glass cloths 24 may, for example be glass-fiber nonwovens, bound with a polymer binder, for example with an acrylate binder. In order to ensure adhesion in the vinyl tile, the glass-fiber nonwovens are coated with polyvinyl chloride. The glass-fiber nonwovens bound with a polymer binder may, for example, each weigh 35 to 50 grams per square meter.
The bottom of the vinyl tile 20 is formed by a polyurethane layer 28 over the whole surface thereof, more specifically, in the example, by a polyurethane foam layer comprising closed cells. In the example, the polyurethane layer 18 has a mass of 90 grams per square meter.
Figure 3 shows a floor covering 40 with floor covering products 41 according to the invention. In the example shown, the floor covering products 41 are square tiles. Other shapes are of course also possible, for example elongated rectangular tiles. These may be carpet tiles (for example as illustrated in Figure 1) or vinyl tiles (for example as illustrated in Figure 2). The floor covering products according to the invention are laid on the floor without an adhesive layer having been applied to the bottom. Due to the polyurethane layer on the underside of the floor covering products, they are still installed properly, the performance of the floor covering being guaranteed for a long time. It is still possible to remove the floor covering products again in an easy manner, for example to place a new floor covering product when one is highly soiled or damaged.
The invention also relates to the following list of numbered sections:

1.- Floor covering product, wherein the floor covering product (10, 20) comprises a wear layer (17), characterized in that the bottom of the floor covering product is formed by a polyurethane layer (18, 28) over at least 50% of its surface, and preferably over its whole surface.
2.- Floor covering product according to section 1, characterized in that the polyurethane layer (18, 28) is a polyurethane foam layer.
3.- Floor covering product according to any one of the preceding sections, characterized in that the polyurethane layer (18, 28) is a polyether polyurethane layer or is a polyester polyurethane layer.
4.- Floor covering product according to any one of the preceding sections, characterized in that the polyurethane layer (18, 28) has a mass of at least 50 grams per square meter, and preferably has a mass of at least 75 grams per square meter.
5.- Floor covering product according to any one of the preceding sections, characterized in that the floor covering product comprises a felt layer (16) - preferably a polyester felt layer -, and that the polyurethane layer (18) contacts the felt layer.
6.- Floor covering product according to section 5, characterized in that the felt layer (16) is a needle felt or a hydroentangled felt.
7.- Floor covering product according sections 5 or 6, characterized in that the felt layer (16) has a mass of at least 100 grams per square meter, and preferably of at least 150 grams per square meter.
8.- Floor covering product according to any one of the preceding sections, characterized in that the wear layer (17) is a resilient wear layer.
9.- Floor covering product according to any one of the preceding sections, characterized in that the floor covering product is a carpet or a carpet tile (10), preferably wherein the carpet tile is a square or an elongated rectangular carpet tile.
10.- Floor covering product according to section 9, characterized in that the wear layer comprises decorative yarns, preferably wherein the decorative yarns are formed by pile yarns (11).
11.- Floor covering product according to section 10, characterized in that the wear layer (17) comprises a primary textile backing (12), wherein the decorative yarns are attached to or in the primary textile backing (12), preferably the primary textile backing (12) is formed by a textile nonwoven or by a woven cloth.
12.- Floor covering product according to section 9, characterized in that the wear layer comprises a felt at the surface of the floor covering.
13.- Floor covering product according to any one of the preceding sections 9 - 12, characterized in that a polymer coating layer (12) is provided on the underside of and contacting the wear layer (17).
14.- Floor covering product according to section 13, characterized in that the polymer coating layer (13) is selected from a styrene acrylate copolymer, a styrene butadiene copolymer, an ethylene vinyl acetate copolymer, a latex, a thermoplastic polymer, or combinations thereof, preferably the polymer coating layer (13) comprises inorganic fillers, for example CaCO₃.
15.- Floor covering product according to any one of the preceding sections 9 - 14, characterized in that the floor covering product (10, 20) comprises a - preferably thermoplastic - secondary backing (14), preferably wherein the secondary backing (14) comprises a bitumen layer or a polymer layer or is formed thereby, more preferably a thermoplastic polymer layer, for example a polyolefin layer.
16.- Floor covering product according to section 15, characterized in that the secondary backing comprises a reinforcement cloth, for example a polyester nonwoven or a glass nonwoven.
17.- Floor covering product according to sections 15 - 16, characterized in that an open glass cloth or a glass nonwoven is pressed on the underside in or against the secondary backing, preferably an open glass cloth wherein the open glass cloth has a polymer-bound fabric of laid glass yarns.
18.- Floor covering product according to any one of the preceding sections 1 - 18, characterized in that the floor covering product (20) comprises a vinyl wear layer (21), preferably formed by a vinyl film - for example by a polyvinyl chloride film -; optionally wherein this vinyl film comprises a lacquer layer, for example an acrylate lacquer layer or a polyurethane lacquer layer.
19.- Floor covering product according to section 18, characterized in that the floor covering product (20) comprises a decoratively printed film (22) under the vinyl wear layer (21).
20.- Floor covering product according to sections 15 or 16, characterized in that the floor covering product comprises multiple vinyl layers (23, 25), preferably filled with inorganic filler, for example with CaCO₃.
21.- Floor covering product according to section 20, characterized in that the floor covering product (20) comprises one or more reinforcement cloths (24), preferably each positioned between two (23, 25) of the multiple vinyl layers.
22.- Floor covering product according to section 21, characterized in that the one or more reinforcement cloths (24) are glass cloths, preferably polymer-bound laid glass fabrics or nonwovens from glass fiber.
23.- Floor covering product according to any one of the preceding sections 18 - 22, characterized in that the floor covering product is a vinyl tile (20), and more preferably a polyvinyl chloride tile.

The present invention is by no means limited to the embodiments described hereinabove, but such floor covering products may be realized according to different variants without going beyond the scope of the present invention.

Claims

Floor covering product, wherein the floor covering product (10, 20) comprises a wear layer (17), characterized in that the bottom of the floor covering product is formed by a polyurethane layer (18, 28) over at least 50% of its surface - and preferably over its whole surface, preferably wherein the polyurethane layer (18, 28) is a polyurethane foam layer.
Floor covering product according to any one of the preceding claims, characterized in that the polyurethane layer (18, 28) is a polyether polyurethane layer or is a polyester polyurethane layer.
Floor covering product according to any one of the preceding claims, characterized in that the polyurethane layer (18, 28) has a mass of at least 50 grams per square meter, and preferably has a mass of at least 75 grams per square meter.
Floor covering product according to any one of the preceding claims, characterized in that the floor covering product comprises a felt layer (16) - preferably a polyester felt layer -, and that the polyurethane layer (18) contacts the felt layer.
Floor covering product according to claim 4, characterized in that the felt layer (16) is a needle felt or a hydroentangled felt.
Floor covering product according claims 4 or 5, characterized in that the felt layer (16) has a mass of at least 100 grams per square meter, and preferably of at least 150 grams per square meter.
Floor covering product according to any one of the preceding claims, characterized in that the wear layer (17) is a resilient wear layer.
Floor covering product according to any one of the preceding claims, characterized in that the floor covering product is a carpet or a carpet tile (10), preferably wherein the carpet tile is a square or an elongated rectangular carpet tile.
Floor covering product according to claim 8, characterized in that a polymer coating layer (12) is provided on the underside of and contacting the wear layer (17).
Floor covering product according to claim 9, characterized in that the polymer coating layer (13) is selected from a styrene acrylate copolymer, a styrene butadiene copolymer, an ethylene vinyl acetate copolymer, a latex, a thermoplastic polymer, or combinations thereof, preferably the polymer coating layer (13) comprises inorganic fillers, for example CaCO₃.
Floor covering product according to any one of the preceding claims 8 - 10, characterized in that the floor covering product (10, 20) comprises a - preferably thermoplastic - secondary backing (14), preferably wherein the secondary backing (14) comprises a bitumen layer or a polymer layer or is formed thereby, more preferably a thermoplastic polymer layer, for example a polyolefin layer; preferably wherein the secondary backing comprises a reinforcement cloth, for example a polyester nonwoven or a glass nonwoven.
Floor covering product according to claim 11, characterized in that an open glass cloth or a glass nonwoven is pressed on the underside in or against the secondary backing, preferably an open glass cloth wherein the open glass cloth has a polymer-bound fabric of laid glass yarns.
Floor covering product according to any one of the preceding claims 1 - 7, characterized in that the floor covering product (20) comprises a vinyl wear layer (21), preferably formed by a vinyl film - for example by a polyvinyl chloride film -; optionally wherein this vinyl film comprises a lacquer layer, for example an acrylate lacquer layer or a polyurethane lacquer layer; preferably wherein the floor covering product (20) comprises a decoratively printed film (22) under the vinyl wear layer (21).
Floor covering product according to claim 13, characterized in that the floor covering product comprises multiple vinyl layers (23, 25), preferably filled with inorganic filler, for example with CaCO₃.
Floor covering product according to claim 14, characterized in that the floor covering product (20) comprises one or more reinforcement cloths (24), preferably each positioned between (23, 25) of the multiple vinyl layers; preferably wherein the one or more reinforcement cloths (24) are glass cloths, more preferably polymer-bound laid glass fabrics or nonwovens from glass fiber.