Stock material or miscellaneous articles – Structurally defined web or sheet – Including stitching and discrete fastener – coating or bond
Patent
1994-01-25
1995-05-16
Bell, James J.
Stock material or miscellaneous articles
Structurally defined web or sheet
Including stitching and discrete fastener, coating or bond
156 93, 156256, 156265, 156324, 428233, 428236, 428246, 428284, 428286, 4289033, B32B 306
Patent
active
054159172
DESCRIPTION:
BRIEF SUMMARY
FIELD OF THE INVENTION
The invention concerns a plane formed body, especially a floor covering, and a process for producing it.
Plane formed bodies are known, for example from EP-A-00890818. They are produced in a process in which a core layer of particles is put between a layer of backing and a cover layer. The cover layer of the plane formed body has an active layer containing fibers that can be punched, and these fibers are needle-punched in through the core layer between the particles, which cannot be punched, into the layer of backing. The core layer is made cohesive with the cover layer and the backing layer first by needle-punching through the three layers. Then, by bonding and vulcanizing the core layer, such a plane formed body obtains an addition binding effect from inside. In the plane formed body described, the core layer consists of unfoamed elastic material, like, for example, granulates of vulcanized rubber, elastomers with or without unfoamed binders, granulates obtained from stitched felt floor coverings and the like. Such plane formed bodies can also be used as flooring coverings.
BACKGROUND OF THE INVENTION
The most common flooring-type coverings consist of a polymerized plastic, mostly of polyvinyl chloride. Because they are very common, the problem of reprocessing or recycling these synthetics is very important. In the past, old used PVC floor coverings were either thrown out or crushed, pulverized and used as additives in producing new materials. The use of such crushed materials is limited, however, since there are losses of quality. Thus, large residual quantities of old PVC coverings must be disposed of.
Another method of recycling reusable PVC is described in DE AS 24 34 925. This concerns a relatively expensive chemical processing of old PVC material.
DE AS 1 179 906 describes a process in which PVC waste material is first pulverized and then pressed onto a fiber backing. The materials have to have a certain composition to result in a usable floor covering.
SUMMARY OF THE INVENTION
The present invention provides a plane formed body, especially a floor covering so that permits especially lumpy polyvinyl chloride to be reused economically and without great expense.
If lumpy polyvinyl chloride material in solid form is used as a core layer between a cover layer and a base layer in a plane formed body, wherein the layers are needle-punched, the result is a way of using PVC plastic waste economically. And cut up PVC sheathing cable can be used (even with Cu or Al cores). The PVC waste material need only be prepared mechanically for further processing, i.e., only appropriate pieces of the plastic material need be produced. This preparatory cycle is simple and, as a rule, can be carried out with no other steps. The plane formed body of the invention also has high quality and good usage properties. Since a fiber layer is worked into solid, soft PVC plastic, the formed body has especially good soundproofing properties and especially high durability. By using old PVC coverings processed into pieces, the use of the old material in the production of new coverings can be increased from roughly 10-20% admixture to 80-100%. By using lumpy material, it is possible to produce a floor covering which has up to 70-90% old PVC material in its top layer and consists of up to 10-15% binding fibers and, if necessary an additive of especially new PVC binders, to fill in intermediate spaces and for additional bonding. The use of larger chip-like pieces that are, for example, 15 mm long, roughly 5 mm wide and between 0.5 and 2 mm thick is especially advantageous. The needles go through these pieces during the sewing process, so that the pieces are fixed simultaneously in their position in the core layer and thus cannot shift. It also eliminates the need for expensive processing of plastic waste into small, quasi-granular pieces. Larger pieces can also be used, and the new plane formed body in the invention has good usage properties, despite this. In addition, pieces this size have the advantage of m
REFERENCES:
patent: 3952126 (1976-04-01), Dycks
patent: 3952126 (1976-04-01), Dycks
patent: 4416936 (1983-11-01), Erickson et al.
patent: 4495235 (1985-01-01), Tesch
patent: 4622260 (1986-11-01), Tesch
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