U.S. patent application number 11/222048 was filed with the patent office on 2006-06-22 for flooring element.
Invention is credited to Wolfgang Mohr, Johann Rosenberger.
Application Number | 20060130416 11/222048 |
Document ID | / |
Family ID | 33483565 |
Filed Date | 2006-06-22 |
United States Patent
Application |
20060130416 |
Kind Code |
A1 |
Mohr; Wolfgang ; et
al. |
June 22, 2006 |
Flooring element
Abstract
The invention relates to a flooring element having improved
sound properties. According to the present invention, the flooring
element consists of several layers, comprising a core layer and a
wear layer which is disposed above the core layer, wherein the core
layer comprises a pressure-resistant wood material and the wear
layer comprises a polymer film. According to the present invention
at least one cork layer which is connected with the core layer is
present. According to the present invention, there is further
provided a flooring element having several layers, comprising a
core layer and a wear layer which is disposed above the core layer,
wherein the core layer contains a pressure-resistant wood material
and the wear layer contains foamed polyvinyl chloride having
heterogeneous structure (cushion vinyl).
Inventors: |
Mohr; Wolfgang;
(Michelstadt, DE) ; Rosenberger; Johann;
(Oberleichtersbach, DE) |
Correspondence
Address: |
MILLEN, WHITE, ZELANO & BRANIGAN, P.C.
2200 CLARENDON BLVD.
SUITE 1400
ARLINGTON
VA
22201
US
|
Family ID: |
33483565 |
Appl. No.: |
11/222048 |
Filed: |
September 9, 2005 |
Current U.S.
Class: |
52/403.1 |
Current CPC
Class: |
B32B 9/04 20130101; B32B
21/08 20130101; E04F 15/10 20130101 |
Class at
Publication: |
052/403.1 |
International
Class: |
E04F 15/22 20060101
E04F015/22 |
Foreign Application Data
Date |
Code |
Application Number |
Sep 9, 2004 |
DE |
20 2004 014 160.4 |
Claims
1. A flooring element having several layers, comprising a core
layer and a wear layer which is disposed above the core layer, said
core layer comprising a pressure-resistant wood material and said
wear layer comprising a polymer film, said flooring element further
comprising at least one cork layer which is connected with the core
layer.
2. The flooring element of claim 1, wherein the cork layer is
disposed below the core layer.
3. The flooring element of claim 1, wherein the cork layer is
disposed between the core layer and the wear layer.
4. The flooring element of claim 2, wherein the cork layer is
disposed between the core layer and the wear layer.
5. The flooring element of claim 1, wherein the cork layer is a
cork granulate layer each.
6. The flooring element of claim 5, wherein the cork layer has a
layer thickness of between 1.0 and 3.0 mm each.
7. The flooring element of claim 1, wherein the polymer film of the
wear layer contains a polymer which is selected from the group
consisting of polyvinyl chlorides, polyesters, polyethylenes,
polyurethanes and polyolefines.
8. The flooring element of claim 7, wherein the polymer film is a
PVC film.
9. The flooring element of claim 1, wherein the polymer film is a
printed or transparent polymer film.
10. The flooring element of claim 9, wherein the transparent
polymer film is printed on the back side.
11. The flooring element of claim 1, wherein the wear layer is a
sandwich of a printed polymer film and a transparent polymer
film.
12. The flooring element of claim 1, wherein the polymer film has a
layer thickness of between 0.15 and 0.70 mm.
13. The flooring element of claim 1, wherein the pressure-resistant
wood material is a medium density fibre board (MDF) or a high
density fibre board (HDF).
14. The flooring element of claim 13, wherein the core layer has a
layer thickness of between 5.0 and 8.0 mm.
15. The flooring element of claim 1, wherein the wear layer
contains a decorative layer.
16. A flooring element having several layers, comprising a core
layer and a wear layer which is disposed above the core layer, said
core layer containing a pressure-resistant wood material and said
wear layer containing foamed polyvinyl chloride having
heterogeneous structure (cushion vinyl).
17. The flooring element of claim 16, wherein the foamed polyvinyl
chloride has a layer thickness of between 2.0 and 3.5 mm.
18. The flooring element of claim 16, wherein a cork layer is
disposed below the core layer.
19. The flooring element of claim 18, wherein the cork layer is a
cork granulate layer.
20. The flooring element of claim 19, wherein the cork layer has a
layer thickness of between 1.0 and 3.0 mm.
21. The flooring element of claim 16, wherein the
pressure-resistant wood material is a medium density fibre board
(MDF) or a high density fibre board (HDF).
22. The flooring element of claim 21, wherein the core layer has a
layer thickness of between 5.0 and 8.0 mm.
23. The flooring element of claim 16, wherein the wear layer
contains a decorative layer.
Description
FIELD OF INVENTION
[0001] The present invention relates to a flooring having several
layers, comprising a core layer (carrier plate) and a wear layer
which is disposed above the core layer.
BACKGROUND OF THE INVENTION
[0002] Hard floorings can be strongly bound to the ground by
adhesive bonding or otherwise fixing or they can be laid in a
floating manner. Hard floorings which were laid in a floating
manner, such as laminate floors, have the disadvantage that at
walking on or loading they give way and set the surrounding air
audibly vibrating. The sound noise which is generated with that is
on the one hand the so-called subsonic sound which at walking on a
flooring reaches the rooms below it and on the other hand the
so-called walking sound, namely the resonance which is emitted
upwards into the room.
[0003] Laminate floorings are known from the state of the art. In
principle, a laminate is a plate or sheet which consists of a core
layer or carrier plate, an antiabrasion layer (protective layer), a
stabilizing layer counter draw layer and a decorative layer which
is often printed with decorative wood patterns. The stabilizing
layer prevents a deformation of the sheet, the antiabrasion
layer--also referred to as overlay--, often a melamine resin
surface, prevents a damage of the decorative layer. However,
colloquially by laminate is meant a flooring which is often used as
a replacement for costly parquet. Laminate floors are featured by
high stressability which is classified into different classes of
stress. Today, almost only laminate floors are produced which can
be laid without any glue, most often in the form of click laminate
with which one panel clicks into place or engages with the
other.
[0004] The laminate fibre boards are formed out of wood fibres or
other lignocellulose materials which are achieved by mechanically
grinding of the raw materials. The process is conducted at a high
temperature in a vapour environment under pressure.
[0005] Especially with the above described laminate floor, the
walking noise which occurs in the form of subsonic sound and
walking sound is found a nuisance (drum effect). Because of this
reason, the different bed plates/webs are used for reducing this
sound. In detail, these are for example wood fibre insulation
layers, rubber mats, rubber cork granulate plates, foamed
polyethylene webs, polyurethane webs, etc. All these bed
plates/webs reduce the subsonic sound, i.e. those sound which
reaches at walking through the ceiling the rooms below it, but they
reduce the walking sound which is emitted from the flooring back
into the room only in a very small amount and the walking noise
will there be found a nuisance.
[0006] Partially the laminate floors are also adhesively laminated
on the back side with insulation sheets/webs. But this also does
not result in a significant reduction of sound in the room. In
addition the disposal of such composite elements creates enormous
problems. As another method, very often an adhesive bonding of the
laminate floor on the ground is conducted which however may lead to
problems for various different reasons. With this manner of sound
protection, for example imperfections during the laying can only be
corrected with great difficulties or even not at all, without
completely removing the covering of the room. However here, the
walking sound is hardly reduced.
[0007] German utility model DE 7236239 U discloses a decorative
plate of a foamed plastic layer and an outer layer forming the
exposed area which may also consist of cork.
[0008] DE 43 32 845 A1 discloses a sound-absorbing ceiling element
with a punched metal sheet having a sound-absorbing coating which
may consist of a foamed plastic film.
[0009] DE 198 51 656 A1 discloses a floor board with which the
subsonic sound should be absorbed. At the underside of the
flooring, there is arranged a sound-absorbing panel for room
respectively subsonic sound insulation. The sound-absorbing panel
may be a composite material of polyurethane bonded rubber
granulates or cork and rubber granulates. This document does not
disclose a flooring element with a wear layer which is disposed on
a core layer and comprises a polymer film.
[0010] German utility model DE 203 11 569 U1 discloses a floor
laminate having a core layer with a wear layer which is disposed
above it, wherein between the core layer and the wear layer a
decorative layer is arranged. Here the core layer may be a HDF
board. The use of a MDF board is not disclosed. The wear layer may
consist of radiation cured polyester.
[0011] German utility model DE 86 18 554 U1 discloses a flooring
element which comprises a wooden core layer with a plastic film
which is disposed above it which may for example consist of
polyethylene. Here the film may be transparent. However with this
construction, there cannot be achieved sufficient sound
properties.
[0012] EP 1 262 607 A1 discloses a floor sheet with a core layer of
wood material, such as for example MDF or HDF, a decorative layer
disposed thereon and a wear layer. Here the wear layer may be a
polyester film and may be transparent, so that the decorative layer
can still be seen.
[0013] In the sense of this application, in this document no
difference is made between subsonic sound and walking sound. The
subsonic sound insulation is effected by a polyurethane coating
which is applied on the back side of the decorative layer, for
example by coating or as a film by adhesive bonding. This
construction is relatively labour-intensive and costly.
Nevertheless, only insufficient sound properties can be achieved
with it.
SUMMARY OF THE INVENTION
[0014] An object of the present invention was to provide a flooring
having improved sound properties which can be laid in an easy
way.
[0015] According to the present invention, the object is solved by
a flooring element having several layers, comprising a core layer
or carrier plate and a wear layer which is disposed above the core
layer, wherein the core layer comprises a pressure-resistant wood
material and the wear layer comprises a polymer film.
[0016] According to a further aspect of the present invention, the
object is solved by a flooring element having several layers,
comprising a core layer or carrier plate and a wear layer which is
disposed above the core layer, wherein the core layer contains or
includes a pressure-resistant wood material and the wear layer
contains or includes foamed polyvinyl chloride (cushion vinyl)
having heterogeneous structure.
[0017] According to a further preferred embodiment, in such a
flooring element between the core layer and the wear layer a cork
layer may be present. Here, in addition at the underside of the
core layer an additional cork layer may be present. Such a cork
layer is preferably formed out of a pressed or bonded cork
granulate layer.
[0018] Surprisingly it was found that with the subject matter of
the present invention a significant reduction of subsonic sound,
ambience sound, structure-borne sound and in particular walking
sound together with a pleasant hearing sensation can be achieved.
At the same time, the energy impacts which are caused by steps are
absorbed and so the walking convenience increases noticeably.
[0019] In addition, all flooring elements according to the present
invention may have lightfast surfaces. So, a fading of the
decorative patterns is prevented and a repositioning of carpets is
always allowed. In addition, a high impact resistance and high
abrasion values can be achieved. Especially both alternative wear
layers of the flooring element according to the present invention
have a significant influence on the quality of the flooring. Shape
stability, insensitivity to pressure and impacts as well as easy
care are the results.
[0020] According to the present invention, as a pressure-resistant
wood material for the core layer a fibre board having medium
density (known on this field as MDF or medium density fibre board)
or a fibre board having high density (known on this field as HDF or
highly compressed fibre board) are used. MDF and HDF boards are
featured by low production costs and at the same time high
loadability and very good processability. MDF or HDF fibre boards
are formed for example under dry conditions, wherein the fibres are
dried prior the formation of the so-called mattress which is
subsequently pressed and treated with heat curing resins without
water and reduced pressure. Due to their consistence, connection
elements, such as for example tongue-groove-connections, can be
formed front-side and/or alongside in an easy and durable
manner.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] In the following, the invention is described in an exemplary
way and with reference to the accompanying drawings by which
further features, advantages and objects to be solved will become
obvious and wherein:
[0022] FIG. 1a shows in a cross-sectional view a flooring element
according to an embodiment of the present invention;
[0023] FIG. 1b shows in a cross-sectional view a flooring element
according to a further embodiment of the present invention;
[0024] FIG. 2 shows in a cross-sectional view a flooring element
according to a further embodiment of the present invention;
[0025] FIG. 3a shows in a cross-sectional view a flooring element
according to a further embodiment of the present invention; and
[0026] FIG. 3b shows in a cross-sectional view a flooring element
according to a further embodiment of the present invention.
[0027] In the figures, identical numerals refer to identical or
equivalent elements or groups of elements.
DETAILED DESCRIPTION OF PREFERRED EXEMPLARY EMBODIMENTS
[0028] FIG. 1a shows a particular embodiment of the flooring
according to the present invention, wherein on the surface of the
core layer 2 a wear layer 1 with polymer film is applied. At the
underside of the core layer 2, a cork layer 3 is disposed.
[0029] FIG. 1b shows a further embodiment of the flooring according
to the present invention, wherein on the surface of the core layer
2 a wear layer 1 of foamed polyvinyl chloride having heterogeneous
structure (cushion vinyl) is applied. At the underside of the core
layer 2, a cork layer 3 is disposed.
[0030] FIG. 2 shows a further embodiment of the flooring according
to the present invention, wherein on the surface of the core layer
2 a cork layer 3' is applied. On the surface of the cork layer 3' a
wear layer with polymer film having heterogeneous structure is
applied. At the underside of the core layer 2, a cork layer 3 is
disposed.
[0031] FIG. 3a shows a further embodiment of the flooring according
to the present invention, wherein on the surface of the core layer
2 a wear layer 1 of foamed polyvinyl chloride having heterogeneous
structure (cushion vinyl) is applied.
[0032] FIG. 3b shows a further embodiment of the flooring according
to the present invention, wherein on the surface of the core layer
2 a wear layer 1 of polymer film is applied.
[0033] Thus, the flooring according to the present invention
comprises several layers. Here one layer is a carrier layer (core
layer). This core layer may consist of pressure-resistant wood
material, for example it may be formed as a medium density (MDF) or
high density or highly compressed (HDF) fibre board. The layer
thickness of the core layer ranges preferably from 5.0 to 8.0 mm.
For the precisely tailored connection of the floorings, the core
layer may in addition have a profile, for example projected edges
or edges for a tongue-groove-connection. This facilitates an easy
laying and a stable connection. These profiles may be disposed
front-side and/or alongside.
[0034] Above the core layer a wear layer is provided. Here, the
wear layer may contain a decorative layer. In one embodiment the
wear layer comprises a polymer film, for example of polyvinyl
chloride, polyester, polyethylene, polyurethane or polyolefin or a
mixture of these polymers.
[0035] In another embodiment, the flooring according to the present
invention comprises a wear layer which contains foamed polyvinyl
chloride having heterogeneous structure (cushion vinyl). Foamed
polyvinyl chloride, also referred to as cushion vinyl, comprises a
foamed core which is arranged between two or more vinyl plies. By
the foamed core, further sound absorption can be achieved. The
foamed polyvinyl chloride may be suitably coloured or printed.
[0036] The polymer film may be a printed or transparent polymer
film. In a particular embodiment of the flooring according to the
present invention, the transparent polymer film may be printed at
the back side. The wear layer which contains a polymer film has
preferably a layer thickness of between 0.15 and 0.70 mm. The wear
layer which contains a foamed polyvinyl chloride has preferably a
layer thickness of between 2.0 and 3.5 mm.
[0037] According to a further embodiment, the wear layer is a
sandwich of a printed polymer film and a transparent polymer film.
Such a composite may be suitably prefabricated in an easy way, for
example in correspondence with the individual demands on the
flooring element, and can then be connected with the core layer in
a suitable manner.
[0038] One embodiment of the flooring according to the present
invention has an additional cork layer below the core layer. In
addition, in a further embodiment of the flooring according to the
present invention, between the core layer and the wear layer a
further cork layer may be present. Here, the cork layers may
consist of a bonded or pressed cork granulate layer.
[0039] The cork layers have preferably a layer thickness of between
1.0 and 3.0 mm each.
[0040] As will be obvious for a person skilled in the art without
further ado, the flooring elements which are shown in the figures
can be fit together to floorings in a suitable manner known from
the state of the art. Due to the low production costs, flooring
elements with a MDF core layer may preferably be used for private
use, whereas flooring elements with the HDF core layers which are
stronger and have a high loadability may preferably be used for
example in the business field.
[0041] Without further elaboration, it is believed that one skilled
in the art can, using the preceding description, utilize the
present invention to its fullest extent. The following preferred
specific embodiments are, therefore, to be construed as merely
illustrative, and not limitative of the remainder of the disclosure
in any way whatsoever.
[0042] In the foregoing and in the following examples, all
temperatures are set forth uncorrected in degrees Celsius and, all
parts and percentages are by weight, unless otherwise
indicated.
[0043] The entire disclosure of all applications, patents and
publications, cited herein and of corresponding German application
No. 20 2004 014 160.4, filed Sep. 9, 2004, is incorporated by
reference herein.
[0044] The preceding examples can be repeated with similar success
by substituting the generically or specifically described reactants
and/or operating conditions of this invention for those used in the
preceding examples.
[0045] From the foregoing description, one skilled in the art can
easily ascertain the essential characteristics of this invention
and, without departing from the spirit and scope thereof, can make
various changes and modifications of the invention to adapt it to
various usages and conditions.
* * * * *