EP3450653A1

EP3450653A1 - Kit for making a floor covering

Info

Publication number: EP3450653A1
Application number: EP17306139.1A
Authority: EP
Inventors: Richard Peres
Original assignee: Tarkett GDL SA
Current assignee: Tarkett GDL SA
Priority date: 2017-09-01
Filing date: 2017-09-01
Publication date: 2019-03-06
Also published as: WO2019043185A1

Abstract

Kit (1) adapted to be assembled on a floor (3) for covering the floor, the kit comprising at least one part (15) adapted for forming a floor covering (17) having a thickness F1 in a direction (V) intended to be perpendicular to the floor when the kit is assembled.

The kit comprises a plurality of substrate elements (13) adapted for being located under the floor covering at least when the kit is assembled.

The thickness F1 is larger than or equal to 1 mm, each of the substrate elements has a same thickness E1, and the substrate elements comprise a material having a Young's modulus higher than 300 MPa.

Description

The present invention deals with a kit adapted to be assembled on a floor for covering the floor, the kit comprising at least one part adapted for forming a floor covering having a thickness F1 in a direction intended to be perpendicular to the floor when the kit is assembled.
It may happen that a floor, for example made of concrete, is not perfectly planar. For example, the floor may have little bumps and cavities. When a kit is assembled for covering such a floor, the resulting floor covering may have an irregular surface, forming "waves". This creates a risk of a person stumbling when walking on such waves. Also, the resulting floor covering shape is often considered as undesirable and unaesthetic.
An aim of the invention is to provide a kit that solves or reduces the problem, while remaining simple to implement, and cost effective.
To this end, the invention proposes a kit adapted to be assembled on a floor for covering the floor, the kit comprising at least one part adapted for forming a floor covering having a thickness F1 in a direction intended to be perpendicular to the floor when the kit is assembled, in which:

the kit further comprises a plurality of substrate elements adapted for being located under the floor covering at least when the kit is assembled,
the thickness F1 is larger than or equal to 1 mm,
each of the substrate elements has a same thickness E1, and
the substrate elements comprise a material having a Young's modulus higher than 300 MPa.

In other embodiments, the kit comprises one or several of the following features, taken in isolation or any technically feasible combination:

the substrate elements comprise polyvinyl chloride or fibrocement;
the thickness E1 is comprised between 3 mm and 12 mm, and/or the thickness F1 is comprised between 5 mm and 30 mm;
said material shows a deformation larger than 0.55 mm when subjected to the following flexure test: obtaining a sample of each of said materials, the sample having a length of 6 cm, a width of 1 cm and a thickness of 0.6 cm in a vertical direction; using a three point flexure machine, for example an Instron® dynamometer, in order to apply a vertical pressure force in the middle of the sample supported by two points of the dynamometer, and obtaining a progressive deformation of the sample lowering by third point of the dynamometer at a constant speed of 0.5 mm/minute in the vertical direction; and recording the applied pressure versus the progressive deformation, the deformation being a value of the progressive deformation when the applied pressure reaches a maximum;
the kit further comprises a connecting system adapted for connecting the substrate elements one to another, the connecting system being adapted to be located in a lower part of the substrate elements when the kit is assembled, the connecting system being preferably adapted to be located a distance D from the floor higher than 1 mm when the kit is assembled;
the floor covering is a resilient thermoplastic covering;
said resilient thermoplastic covering comprises at least 25 wt% of PVC;
the thickness F1 is comprised between 2 mm and 7 mm;
the floor covering comprises: a plurality of separate parts, each of the parts being respectively fixed on one of the substrate elements so as to form a tile having a length between 250 mm and 2000 mm, and a width between 80 mm and 1000 mm; or at least one roll adapted for being unrolled along an unfolding direction in order to form at least said part of the floor covering over the substrate elements when the kit is assembled, the part having a width between 1 m and 5 m perpendicularly to the unfolding direction;
the floor covering comprises more than 50 wt% of wood;
the floor covering is a laminate wood covering or an engineered wood covering;
the floor covering comprises a plurality of separate parts, each of the parts being respectively fixed on one of the substrate elements so as to form a tile having a length between 250 mm and 2000 mm, and a width between 80 mm and 1000 mm;
the floor covering is a carpet;
the floor covering comprises more than 50 wt% of ceramic; and
the thickness F1 is comprised between 7 mm and 15 mm.

The invention and its advantages will be better understood upon reading the following description, given solely by way of example and with reference to the appended drawings, in which:

Figure 1 is a schematic upper view of a kit according to a first embodiment of the invention, the kit being in an assembled configuration,
Figure 2 is a schematic sectional view of the kit shown in Figure 1 along a vertical plane,
Figure 3 is a schematic sectional view of a kit according to a second embodiment of the invention, the kit being in an assembled configuration, and
Figure 4 is a schematic upper view of a floor covering obtained with the kit represented in Figure 3.

With reference to Figure 1 and 2, a kit 1 according to a first embodiment of the invention is described.
The kit 1 is adapted for being assembled on a horizontal floor 3 in order to form a floor covering 5 having a thickness E along a vertical direction V.
By "floor covering" it is meant one or several elements, in this embodiment several, adapted for covering a floor, at least partly, and advantageously totally.
The floor 3 for example defines a cavity 4.
The thickness E for example ranges between 8 mm and 42 mm.
When not assembled, the kit 1 is for example stored in several boxes (not represented).
As a variant (not shown), the kit 1 may be assembled on another surface, for example defined by a wall (not shown).
The kit 1 comprises a plurality of tiles 7, and a connecting system 11 (Figure 2). The tiles 7 have the same composition, and for example the same shape as shown in Figure 1, advantageously a rectangular one. The tiles 7 have a length L1 (Figure 1) along a longitudinal direction L perpendicular to the direction V, and a width LL1 along a transversal direction T perpendicular to the longitudinal direction and the vertical direction V.
For example L1 ranges between 250 mm and 2000 mm.
For example LL1 ranges between 80 mm and 1000 mm.
Each of the tiles 7 comprises a substrate element 13 extending perpendicularly to the direction V and having a thickness E1, and an upper part 15 arranged, for example fixed, on the substrate element and having a thickness F1 (Figure 2).
All the parts 15 are separate from each other in this embodiment.
Each of the parts 15 is advantageously, in itself, a floor covering element which would be adapted for covering a floor without any additional layer. Such a floor covering element usually comprises a core layer (not represented), one or more decoration layers (not represented), and optionally one or several wear layers (not represented) adapted to increase the durability of the floor covering. Such a floor covering element is usually directly applied on a floor.
Altogether, the parts 15 form a floor covering 17 having the thickness F1 when the kit 1 is assembled.
The thickness E1 is for example comprised between 3 mm and 12 mm.
The thickness F1 is larger than or equal to 1 mm, so that the parts 15 forming the floor covering 17 must not been mistaken with thin (less than 1 mm) decorative layers that would be unfit to be directly applied on a floor.
In fact, the thickness F1 is advantageously comprised between 5 mm and 30 mm.
Each of the substrate elements 13 for example consist of one layer made of a material having a Young's modulus higher than 300 MPa.
Said material advantageously shows a deformation larger than 0.55 mm when subjected to the following flexure test.
A sample of the material to be tested is obtained, the sample having a length of 6.0 cm, a width of 1.0 cm and a thickness of 0.6 cm in a vertical direction.
A three point flexure machine, for example an Instron® dynamometer, is then used. Two points, separated by a horizontal distance of 5.0 cm, support the sample. A vertical pressure force is applied by the third point in the middle of the sample and a progressive deformation of the sample in the vertical direction is obtained by lowering the third point at a constant speed of 0.5 mm/minute.
The applied pressure, in N, is recorded versus the progressive deformation, in mm. The applied pressure first increases, then reaches a maximum, and finally decreases.
The deformation is the value, in mm, of the progressive deformation when the applied pressure reaches its maximum.
The above mentioned Young's modulus can advantageously be determined using the slope of the curve representing the applied pressure versus the progressive deformation, the slope being assessed at the very beginning of the progressive deformation.
Each of the substrate elements 13 may comprise polyvinyl chloride (PVC) or fibrocement, preferably at least 20wt%.

The substrate elements 13 may have the composition defined in the following table.

	Material	Name	Supplier	PHR	%
1	PVC	Vynova 5730	Vynova	100	27.8
2	CaCO3 Filler	OMYA VS35	OMYA	250	69.5
3	Stabilizer	Baeropan 90704P	Baerlocher	4.5	1.3
4	Processing aid (CPE)	Durastrength 200 or 3000	Arkema	3.0	0.8
5	Processing Aid	Plastistrength 530	Arkema	1.0	0.3
6	Processing aid (PE Wax)	A-C629	Honeywell	0.5	0.1
7	Processing aid (Stearic Acid)	Stearina RG	Brentag	0.5	0.1
			Total:	359.5	100.0

The parts 15 may be a resilient thermoplastic covering, for example comprising at least 25 wt% of PVC, with the thickness F1 advantageously comprised between 2 mm and 7 mm.
For resilient floor coverings, reference is made to the norm EN ISO 10581 of October 2013.
The parts 15 may comprise more than 50 wt% of wood, as represented in Figure 2. The part 15 may be a laminate wood covering or an engineered wood covering (multi-layer parquet).
For wood floor coverings, reference is made to the norms EN 13489 of December 2002 (engineered wood, multi-layer parquet) and EN 13329:2006+A1 of October 2008 (laminate floor covering).
The parts 15 may be a carpet, i.e. a textile floor covering, for which reference is made to the norm EN 1307 of May 2014.
The parts 15 may comprise more than 50 wt% of ceramic, with the thickness F1 advantageously comprised between 7 mm and 15 mm.
For ceramic floor coverings, reference is made to the norm EN 14411 of December 2012.
The connecting system 11 is adapted for connecting the substrate elements 13 one to another. The connecting system 11 is adapted to be located in a lower part of the substrate elements 13 when the kit 1 is assembled.
The connecting system 11 is preferably located a distance D from the floor 3, D being higher than 1 mm when the kit 1 is assembled.
The connecting system 11 is advantageously integral with the substrate elements 13. For example, it comprises hooks and housings (not shown) defined by the substrate elements 13 and adapted to cooperate with each other in a snap-fit manner.
As a variant (not shown), the connecting system 11 comprises connecting members (not shown), for example bars, that are not integral with the substrate elements 13, and are adapted to cooperate with the housings defined by the substrate elements 13 in a snap-fit manner.
Thanks to the above features, in particular their rigidity, the tiles 7 form a sufficiently planar floor covering 5 despite defects such as the cavity 4 in the floor 3. As a consequence, the kit 1 solves or reduces the problem of levelling a floor having nonplanar defects.
A kit 100 according to a second embodiment of the invention will now be described with reference to Figures 3 and 4. The kit 100 is analogous to the kit 1 shown in Figures 1 and 2. Identical elements bear the same numeral references in the drawings and will not be described again. Only the differences will be described in detail hereafter.
In the kit 100, the floor covering 17 is not made of separate parts 15 directly arranged on the substrate elements 13. The kit 1 comprises the substrate elements 13, at least one roll 115, and the connecting system 11.
For example, the floor covering 17 comprises several parts 117 obtained by unrolling the roll 115, or another roll analogous to the roll 115, along an unfolding direction T1, and by cutting the roll several times.
In the example, the unfolding direction T1 is parallel to the transversal direction T, and the cuts are made along the longitudinal direction L.
The substrate elements 13 still have the length L1 (Figure 4) along the longitudinal direction L, and the width LL1 along the transversal direction T, like the tiles 7 in Figure 1.
The floor covering parts 117 have a length L2 along the transversal direction T, and a width LL2 along the longitudinal direction L.
For example LL2 ranges between 1 m and 5 m.
The length L2 may be arbitrarily long, depending on how the roll 115 is unrolled and cut.
The parts 117 are for example fixed to the substrate elements 13, advantageously using a glue (not represented).
The parts 117 may be a resilient thermoplastic covering, as shown in Figure 3, for example comprising at least 25 wt% of PVC, with the thickness F1 advantageously comprised between 2 mm and 7 mm.
The parts 117 may be a carpet.
The kit 100 brings the same advantages as the kit 1 in terms of leveling potential defects of the floor 3.

Claims

Kit (1;100) adapted to be assembled on a floor (3) for covering the floor (3), the kit comprising at least one part (15;117) adapted for forming a floor covering (17) having a thickness F1 in a direction (V) intended to be perpendicular to the floor (3) when the kit (1;100) is assembled, characterized in that:
- the kit (1;100) further comprises a plurality of substrate elements (13) adapted for being located under the floor covering (17) at least when the kit (1;100) is assembled,

- the thickness F1 is larger than or equal to 1 mm,

- each of the substrate elements (13) has a same thickness E1, and

- the substrate elements (13) comprise a material having a Young's modulus higher than 300 MPa.
Kit (1;100) according to claim 1, in which the substrate elements (13) comprise polyvinyl chloride or fibrocement.
Kit (1;100) according to claim 1 or 2, in which:
- the thickness E1 is comprised between 3 mm and 12 mm, and/or

- the thickness F1 is comprised between 5 mm and 30 mm.
Kit (1;100) according to any of claims 1 to 3, in which said material shows a deformation larger than 0.55 mm when subjected to the following flexure test:
- obtaining a sample of each of said materials, the sample having a length of 6 cm, a width of 1 cm and a thickness of 0.6 cm in a vertical direction,

- using a three point flexure machine, for example an Instron® dynamometer, in order to apply a vertical pressure force in the middle of the sample supported by two points of the dynamometer, and obtaining a progressive deformation of the sample lowering by third point of the dynamometer at a constant speed of 0.5 mm/minute in the vertical direction, and

- recording the applied pressure versus the progressive deformation,
the deformation being a value of the progressive deformation when the applied pressure reaches a maximum.
Kit (1;100) according to any of claims 1 to 4, further comprising a connecting system (11) adapted for connecting the substrate elements (13) one to another, the connecting system (11) being adapted to be located in a lower part of the substrate elements (13) when the kit is assembled, the connecting system (11) being preferably adapted to be located a distance D from the floor (3) higher than 1 mm when the kit (1;100) is assembled.
Kit (1;100) according to any of claims 1 to 5, in which the floor covering (17) is a resilient thermoplastic covering.
Kit (1;100) according to claim 6, wherein said resilient thermoplastic covering comprises at least 25 wt% of PVC.
Kit (1;100) according to claim 7, wherein the thickness F1 is comprised between 2 mm and 7 mm.
Kit (1;100) according to any of claims 6 to 8, in which the floor covering (17) comprises:
- a plurality of separate parts (15), each of the parts (15) being respectively fixed on one of the substrate elements (13) so as to form a tile (7) having a length (L1) between 250 mm and 2000 mm, and a width (LL1) between 80 mm and 1000 mm, or

- at least one roll (115) adapted for being unrolled along an unfolding direction (T1) in order to form at least said part (117) of the floor covering (17) over the substrate elements (13) when the kit (1;100) is assembled, the part (117) having a width (LL2) between 1 m and 5 m perpendicularly to the unfolding direction (T1).
Kit (1;100) according to any of claims 1 to 5, in which the floor covering (17) comprises more than 50 wt% of wood.
Kit (1;100) according to claim 10, wherein the floor covering (17) is a laminate wood covering or an engineered wood covering.
Kit (1;100) according to claim 11, wherein the floor covering (17) comprises a plurality of separate parts (15), each of the parts (15) being respectively fixed on one of the substrate elements (13) so as to form a tile (7) having a length (L1) between 250 mm and 2000 mm, and a width (LL1) between 80 mm and 1000 mm.
Kit (1;100) according to any of claims 1 to 5, in which the floor covering (17) is a carpet.
Kit (1;100) according to any of claims 1 to 5, in which the floor covering (17) comprises more than 50 wt% of ceramic.
Kit (1;100) according to claim 14, wherein the thickness F1 is comprised between 7 mm and 15 mm.