U.S. patent application number 10/779426 was filed with the patent office on 2004-08-19 for web-type floor covering and method for its manufacture.
Invention is credited to Graab, Gerhard, Heckel, Klaus, Heidecke, Gerhard, Rischer, Dieter.
Application Number | 20040161589 10/779426 |
Document ID | / |
Family ID | 7903810 |
Filed Date | 2004-08-19 |
United States Patent
Application |
20040161589 |
Kind Code |
A1 |
Graab, Gerhard ; et
al. |
August 19, 2004 |
Web-type floor covering and method for its manufacture
Abstract
A web-type floor covering made of vulcanized rubber that
includes an elastic rubber web, the top side of which forms a
decorative surface, first decorative particles being at least
partially embedded in the rubber web so that the first decorative
particles are visible from the top side, a transparent coating, in
particular made of epoxy resin, being applied to the first
decorative particles on at least part of their contact surface with
the rubber web, the first decorative particles being preferably
made of a different material from that used for the rubber web.
Inventors: |
Graab, Gerhard; (Mannheim,
DE) ; Heckel, Klaus; (Gorxheimertal, DE) ;
Rischer, Dieter; (Abtsteinach, DE) ; Heidecke,
Gerhard; (Bensheim, DE) |
Correspondence
Address: |
KENYON & KENYON
One Broadway
New York
NY
10004
US
|
Family ID: |
7903810 |
Appl. No.: |
10/779426 |
Filed: |
February 13, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10779426 |
Feb 13, 2004 |
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09542234 |
Apr 4, 2000 |
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6709732 |
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Current U.S.
Class: |
428/143 |
Current CPC
Class: |
Y10T 428/31826 20150401;
Y10T 428/256 20150115; Y10T 428/2991 20150115; B44C 5/043 20130101;
Y10T 428/2998 20150115; Y10T 428/24413 20150115; E04F 15/10
20130101; Y10T 428/254 20150115; B44C 5/0415 20130101; B44C 5/04
20130101; B29C 70/64 20130101; Y10T 428/24372 20150115; Y10T
428/2438 20150115; Y10T 428/24405 20150115; B44F 1/02 20130101;
Y10T 428/3183 20150401 |
Class at
Publication: |
428/143 |
International
Class: |
B32B 001/00 |
Foreign Application Data
Date |
Code |
Application Number |
Apr 8, 1999 |
DE |
199 15 729.4 |
Claims
What is claimed is:
1. A web-type floor covering comprising: a vulcanized rubber web
having a top side that provides a decorative surface; a plurality
of first decorative particles that are at least partially embedded
in the rubber web along contact surfaces with the rubber web, the
first decorative particles being visible from the top side; wherein
a transparent coating, in particular made of epoxy resin, coats the
first decorative particles on at least part of the contact surface
between the rubber web and the decorative particles, the first
decorative particles being preferably made of a different material
from that used for the rubber web.
2. The floor covering according to claim 1, wherein the first
decorative particles are at least partly made of a highly
light-reflective material.
3. The floor covering according to claim 2, wherein the first
decorative particles are made of a material selected from the group
consisting of corundum, silicon carbide and aluminum.
4. The floor covering according to claim 1, wherein the first
decorative particles are irregularly shaped.
5. The floor covering according to claim 3, wherein the first
decorative particles are irregularly shaped.
6. The floor covering according to claim 1, wherein the first
decorative particles have a height as well as transverse and
longitudinal dimensions, and the height of at least part of the
first decorative particles is not as great as their longitudinal
and transverse dimensions.
7. The floor covering according to claim 1, wherein the size of the
first decorative particles 5 is between 0.05 and 5 mm, and
preferably between 0.25 mm and 0.70 mm.
8. The floor covering according to claim 6, wherein the size of the
first decorative particles 5 is between 0.05 and 5 mm, and
preferably between 0.25 mm and 0.70 mm.
9. The floor covering according to claim 1, wherein the coating, in
particular the epoxy resin, is applied to the first decorative
particles and cured, and these are then applied to the top side of
an uncured rubber web, and the rubber web is then vulcanized.
10. The floor covering according to claim 3, wherein the coating,
in particular the epoxy resin, is applied to the first decorative
particles and cured, and these are then applied to the top side of
an uncured rubber web, and the rubber web is then vulcanized.
11. Floor covering according to claim 1, wherein second decorative
particles made of rubber and having no coating are provided.
12. Floor covering according to claim 8, wherein second decorative
particles made of rubber and having no coating are provided.
13. A method for manufacturing a web-type floor covering comprising
the steps of: preparing a quantity of first decorative particles, a
coating, in particular made of epoxy resin, having being applied in
advance to at least part of the particles; preparing an uncured
rubber web having a top side; applying the decorative particles to
the top side of the rubber web; attaching the decorative particles
to the rubber web via application of pressure; vulcanizing the
rubber web having the decorative particles.
14. An elastic rubber floor covering comprising decorative
particles coated with epoxy resin manufactured by the method set
forth in claim 13.
Description
TECHNICAL FIELD
[0001] The present invention relates to a web-type floor covering
made of vulcanized rubber that includes an elastic rubber web,
whose top side forms a decorative surface, first decorative
particles being at least partially embedded in the rubber web so
that the first decorative particles are visible from the top
side.
BACKGROUND OF THE INVENTION
[0002] A web-type floor covering of this kind is described in
German Patent 39 42 505 C1. German Patent 39 42 505 C1 proposes
that particles made of ground rubber stock be used as the
decorative particles. Herein, good adhesion between the decorative
particles and the rubber web can be achieved. However, if a
different material is used for the decorative particles instead of
ground rubber stock, when rubbing tests are performed they indicate
that decorative particles of this kind do not adhere satisfactorily
to the rubber web and therefore may become detached when subjected
to frictional loads.
SUMMARY OF THE INVENTION
[0003] The object of the present invention is therefore to improve
adhesion between the decorative particles and the rubber web and
thus ensure that a minimum of decorative particles are detached.
According to the present invention, this object is achieved as
follows: A transparent coating, in particular made of epoxy resin,
is applied to a given first decorative particle on at least part of
its contact surface with the rubber web, the first decorative
particles preferably being made of a different material from that
used for the rubber web. Thanks to the coating, which may be
applied to the entire contact surface or just parts thereof,
materials that would otherwise not form a lasting and
friction-resistant bond with the rubber web can be used for the
decorative particles. Thus the present invention allows one to use
novel materials for the decorative particles of a floor covering
made of rubber, so that novel aesthetic effects can be achieved.
The manufacturing processes are straightforward, provided epoxy
resin is used; in addition, the decorative particles adhere well
and lastingly.
[0004] According to a further refinement of the present invention,
the first decorative particles are at least partly made of a highly
light-reflective material. According to the present invention,
particles that have a sparkling, i.e., metallic or quasi-metallic,
appearance can be used for the first time for a floor covering made
of rubber, because it is thanks to the coating that they form a
strong bond with the rubber surface.
[0005] In particular, strong adhesion can be achieved if the coated
first decorative particles are made of corundum, silicon carbide
and/or aluminum. Coated aluminum particles can in particular be
used as aluminum spangles, which can be manufactured by fragmenting
an aluminum foil coated with epoxy resin. The advantage of aluminum
is that it is relatively soft, which means the floor covering is
easy to cut.
[0006] Adhesion can be further improved if the first decorative
particles are not regularly shaped. Alternatively, according to the
present invention, regularly shaped decorative particles, e.g.,
having a square, rectangular or circular basal plane, may be
permanently bonded to the rubber surface.
[0007] To achieve a largely flat surface, it is advantageous if the
height of at least part of the first decorative particles is not as
great as their longitudinal and transverse dimensions.
[0008] Furthermore, according to the present invention, the size of
the first decorative particles is between 0.05 and 5 mm, preferably
between 0.25 mm and 0.70 mm. The size of the decorative particles
can be determined using a microscope, or via screen analysis.
[0009] Furthermore, according to the present invention, the
coating, in particular the epoxy resin, is applied to the first
decorative particles and cured, and the particles are then applied
to the top surface of an uncured rubber web, and the rubber web is
then vulcanized.
[0010] Furthermore, according to the present invention, second
decorative particles made of rubber and having no coating may be
used.
[0011] Furthermore, the present invention relates to a method for
manufacturing a web-type floor covering having the following
steps:
[0012] Preparation of decorative particles, a coating, in
particular made of epoxy resin, having being applied in advance to
at least part of the particles; preparation of an uncured rubber
web having a top side; application of the decorative particles to
the top side, in particular via scattering; attachment of the
decorative particles to the rubber web via application of pressure;
and vulcanization of the rubber web having the decorative
particles.
[0013] Furthermore, the present invention relates to the use of
decorative particles coated with epoxy resin in the manufacture of
an elastic floor covering made of rubber.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] An exemplary embodiment of the present invention is shown in
the drawings, in which:
[0015] FIG. 1 is a top plan view of a floor covering according to
the present invention; and
[0016] FIG. 2 is a cross-sectioned view taken through a floor
covering according to the present invention.
DETAILED DESCRIPTION OF THE PRESENT INVENTION
[0017] FIGS. 1 and 2 schematically depict a web-type floor covering
1, which is essentially formed from rubber web 2, the top surface 3
of which provides forms a decorative surface. Bottom surface 4 of
floor covering 1 is placed on the floor to be covered and can, for
example, be permanently bonded to it via adhesive bonding.
[0018] First and second decorative particles 5, 6 are embedded in
rubber web 2 so that decorative particles 5, 6 are visible from top
side 3. Herein, first and second decorative particles 5, 6 are
arranged on the surface of the rubber web so that they form part of
the surface of floor covering 1.
[0019] First decorative particles 5 are made of a highly
light-reflective material, e.g., corundum, silicon carbide,
aluminum, or a mixture of various different materials. Highly
light-reflective first decorative particles 5 give floor covering 1
a variable sparkling appearance when it is viewed from different
angles. A coating made of epoxy resin is applied to decorative
particles 5. The coating is transparent, and in particular is clear
and may be colored to produce color effects. If first particles 5
are made of aluminum, one can manufacture them particularly easily
by first coating an aluminum foil with epoxy resin and then
fragmenting it. The epoxy resin may also be applied to first
decorative particles 5 via other methods, e.g., via spraying or
immersion. First decorative particles 5 are made of a material that
is not rubber and is thus different from the material used for
rubber web 2.
[0020] First decorative particles 5 may be regularly shaped, e.g.,
they may have a square, rectangular, or circular basal plane. The
height of first decorative particles 5 is not as great as their
longitudinal and transverse dimensions. The size of a given first
decorative particle 5 is between 0.05 and 5 mm, preferably between
0.25 mm and 0.70 mm.
[0021] Second decorative particles 6 are made of rubber. Second
decorative particles 6 of this kind form a strong bond with rubber
web 2 even without an epoxy resin coating; second decorative
particles 6 therefore do not require an epoxy resin coating. The
size of second decorative particles 6 is between 0.3 mm and 1.5 mm,
preferably between 0.5 mm and 1.0 mm, this being determined via
screen analysis.
[0022] The rubber mixture for rubber web 2 and/or second decorative
particles 6 may be manufactured from a rubber mixture that is known
heretofore. An example of a rubber mixture of this kind is shown
below:
1 Styrene/butadiene rubber (styrene content: 100 parts 23%)
Styrene/butadiene copolymer (styrene content: 20 parts 85%)
Precipitated silicic acid 40 parts Kaolin 70 parts Precipitated
chalk 30 parts Coumarone-indene resin 15 parts Zinc oxide 5 parts
Stearic acid 1.5 parts Sulfur 2.5 parts Polyethylene glycol 3.0
parts Cyclohexylbenzthiazylsulfenamide 2.7 parts Tetramethylthiuram
disulfide] 0.5 parts
[0023] Second decorative particles 6 may be created by fragmenting
a vulcanized and in particular web-type rubber mass. However, they
may also be made of unvulcanized rubber particles, which may be
either single-colored or multi-colored.
[0024] The floor covering according to the present invention is
manufactured via the following steps. First, first decorative
particles 5 are prepared, epoxy resin having being applied in
advance to at least part of the particles. Furthermore, uncured
calendered rubber web 2 is prepared. First decorative particles 5
and if necessary second decorative particles 6 are applied to the
top side thereof. This may be accomplished by scattering the
decorative particles. After that, decorative particles 5, 6 are
attached to rubber web 2 via application of pressure, the
decorative particles being, for example, pressed into rubber web 2
by a heated steel cylinder until they are at least partially
embedded. Finally, rubber web 2 having decorative particles 5, 6 is
vulcanized, decorative particles 5, 6 thus being permanently bonded
to the surface of rubber web 2. Alternatively, decorative particles
5, 6 can be mixed into rubber web 2 before calendering, so that
they are provided not just on its top side but distributed
throughout its entire cross section. This means that the appearance
of the upper layer of the floor covering does not change even if it
is subject to wear and tear.
[0025] An adhesion test of decorative particles 5, 6 can be carried
out as follows: The decorative side 3 of a piece of floor covering
measuring 10.times.10 cm is rubbed against the decorative side of a
second similarly dimensioned piece. Herein, to pass the test, it is
necessary that no more than a few decorative particles, or no
particles at all, become detached from rubber web 2. Herein, the
floor coverings according to the present invention display
excellent values, so that they may be used even if the floor in
question is subject to intensive use, e.g., in public
buildings.
* * * * *