U.S. patent application number 12/251013 was filed with the patent office on 2009-06-18 for floor covering with viscoelastic dampening properties.
This patent application is currently assigned to Bayer MaterialScience AG. Invention is credited to Hans Johann Klunter, Sven Meyer-Ahrens, Semka Muratovic, Rolf Roers, Ralph Schneider, Sebastien Triouleyre.
Application Number | 20090155520 12/251013 |
Document ID | / |
Family ID | 40174792 |
Filed Date | 2009-06-18 |
United States Patent
Application |
20090155520 |
Kind Code |
A1 |
Roers; Rolf ; et
al. |
June 18, 2009 |
FLOOR COVERING WITH VISCOELASTIC DAMPENING PROPERTIES
Abstract
The present invention concerns a floor covering, such as a
carpet, containing a first textile planar element and a first layer
which is at least partially connected to the first textile planar
element over their surfaces, wherein the first layer contains
viscoelastic polymer foam. The floor covering according to the
invention is characterized in that the first textile planar element
has a modulus of elasticity of .gtoreq.0.5 N/mm.sup.2 to
.ltoreq.2.5 N/mm.sup.2, that in the first layer 1 the viscoelastic
polymer foam has a compression load deflection at 40% compression
of .gtoreq.1 kPa to .ltoreq.10 kPa and that in the first layer the
viscoelastic polymer foam has a hysteresis when determining the
compression load deflection at 40% compression of .gtoreq.20% to
.ltoreq.70%. The present invention also relates to a method of
manufacturing a floor covering.
Inventors: |
Roers; Rolf; (Odenthal,
DE) ; Triouleyre; Sebastien; (Koln, DE) ;
Meyer-Ahrens; Sven; (Leverkusen, DE) ; Schneider;
Ralph; (Koln, DE) ; Muratovic; Semka;
(Detmold, DE) ; Klunter; Hans Johann; (Koln,
DE) |
Correspondence
Address: |
CONNOLLY BOVE LODGE & HUTZ, LLP
P O BOX 2207
WILMINGTON
DE
19899
US
|
Assignee: |
Bayer MaterialScience AG
Leverkusen
DE
|
Family ID: |
40174792 |
Appl. No.: |
12/251013 |
Filed: |
October 14, 2008 |
Current U.S.
Class: |
428/95 |
Current CPC
Class: |
D06N 2205/20 20130101;
D06N 2209/1628 20130101; D06N 2211/12 20130101; D06N 7/0086
20130101; D06N 7/0073 20130101; Y10T 428/23979 20150401; D06N
7/0081 20130101; D06N 2205/04 20130101; D06N 2203/068 20130101;
D06N 2209/065 20130101; D06N 2209/067 20130101 |
Class at
Publication: |
428/95 |
International
Class: |
D04H 11/00 20060101
D04H011/00; D03D 27/00 20060101 D03D027/00 |
Foreign Application Data
Date |
Code |
Application Number |
Oct 15, 2007 |
DE |
102007049506.6 |
Sep 10, 2008 |
DE |
102008046667.0 |
Claims
1. A floor covering comprising a first textile planar element and a
first layer which is at least partially connected to the first
textile planar element over their surfaces, wherein the first layer
comprises viscoelastic polymer foam, wherein the first textile
planar element has a modulus of elasticity of .gtoreq.0.5
N/mm.sup.2 to .ltoreq.2.5 N/mm.sup.2, that in the first layer the
viscoelastic polymer foam has a compression load deflection at 40%
compression of .gtoreq.1 kPa to .ltoreq.10 kPa and that in the
first layer the viscoelastic polymer foam has a hysteresis when
determining the compression load deflection at 40% compression of
.gtoreq.20% to .ltoreq.70%.
2. The floor covering according to claim 1, wherein the
viscoelastic polymer foam of the first layer is a polyurethane
foam.
3. The floor covering according to claim 1, wherein the
viscoelastic polymer foam of the first layer is a cross-linked
frothed foam from synthetic or natural latex.
4. The floor covering according to claim 1, wherein the material of
the first textile planar element comprises polyurethane and/or
thermoplastic polyurethane.
5. The floor covering according to claim 1, wherein the connection
between the first textile planar element and the first layer is
effected by an elastomeric adhesive.
6. The floor covering according to claim 1, further comprising
fibers which penetrate the first textile planar element and into
the first layer and wherein the fibers are anchored in the first
layer by an elastomeric adhesive.
7. The floor covering according to claim 1, wherein the First layer
additionally comprises an embedded second textile planar element
which has a modulus of elasticity of .gtoreq.1000 N/mm.sup.2 to
.ltoreq.2000 N/mm.sup.2.
8. The floor covering according to claim 1, further comprising a
second layer arranged on the side of the first layer which is
opposite to the first textile planar element and which is at least
partially connected to the first layer, wherein the second layer
comprises polymer foam which has a compression load deflection at
40% compression of .gtoreq.15 kPa to .ltoreq.150 kPa.
9. The floor covering according to claim 8, further comprising a
third textile planar element which has a modulus of elasticity of
.gtoreq.1000 N/mm.sup.2 to .ltoreq.2000 N/mm.sup.2, wherein the
third textile planar element is arranged on the side of the second
layer which is opposite to the first layer and wherein the third
textile planar element is at least partially connected to the
second layer.
10. The floor covering according to claim 1, further comprising
microencapsulated fragrances.
11. A method for manufacturing a floor covering according to claim
1, comprising the step of back-foaming the first textile planar
element with a reaction mixture leading to the polymer foam of the
first layer.
12. The method according to claim 11, wherein the reaction mixture
comprises a polyol and an isocyanate.
13. The method according to claim 11, wherein the reaction mixture
comprises a prepolymer and water.
Description
RELATED APPLICATIONS
[0001] This application claims benefit to German applications No.
DE 10 2007 049 506.6, filed on Oct. 15, 2007 and DE 10 2008 046
667.0, filed on Sep. 10, 2008 which are incorporated by reference
in their entirety for all useful purposes.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention concerns a floor covering, comprising
a first textile planar element and a first layer which is at least
partially connected to the first textile planar element over their
surfaces, wherein the first layer comprises viscoelastic polymer
foam. Such floor coverings may be, for example, carpets. The
present invention further concerns a method for manufacturing such
a floor covering.
[0004] 2. Description of the Prior Art
[0005] Carpets may be employed in a variety of uses. In private or
commercial housing spaces they can be used for heat and acoustical
insulation besides being used for decorative purposes. One
possibility to manufacture carpets is to anchor fibers in a carpet
backing and then to subsequently back-foam the carpet backing on
its rear side.
[0006] It is generally known to back-foam carpet backings with a
viscoelastic foam. In this respect, DE 33 13 624 A1 discloses a
flexible polyurethane foam for acoustical insulation purposes, a
method for its manufacture and the use thereof. The described
flexible polyurethane foam for acoustical insulation purposes with
a density of less than 90 kg/m.sup.3 and a modulus of elasticity of
less than 106 N/m.sup.2 has a loss factor of at least 0.3 and
viscoelastic properties in a temperature range of -20.degree. C. to
+80.degree. C.
[0007] The flexible foam can be obtained by reacting an isocyanate
with a polyol, wherein the polyol has at least one component with
an OH number of 180 to 400. The foam is especially suitable for the
absorption and dampening of airborne sound and for the dampening of
solid-borne sound. According to this disclosure, the flexible
polyurethane foam can be used for back-foaming the cowl or floor
carpet of automobiles. In an embodiment, a specially prepared
carpet, optionally with acoustical insulation sheets, was added to
the foaming mould in order to reach a sufficient foam density.
After application of the usual separating agent the reaction
mixture was added with the mould covering closed. 2.5 to 3 minutes
thereafter the formed article could be removed.
[0008] DE 39 42 330 A1 discloses a method for manufacturing
flexible polyurethane soft foams with viscoelastic and solid-borne
sound dampening properties in a temperature range of -20.degree. C.
to +80.degree. C. by reacting a) a polyoxyalkylene polyol mixture
comprising ai) special block polyoxypropylene-polyoxyethylene
polyol mixtures with a hydroxyl number from 14 to 65 and a content
of terminally bound ethylene oxide units from 2 to 9 weight-%,
which can themselves be obtained by using a starter mixture with an
average functionality of 2.2 to 2.8, consisting of water and
glycerine or trimethylol propane or of water and glycerine and
trimethylol propane and aii) at least one di- or trifunctional
polyoxypropylene polyoxyethylene polyol with a content of
oxyethylene units from 60 to 85 weight-% relative to the total
weight of polymerizable alkylene oxide units, and a hydroxyl number
from 20 to 80; b) optionally low molecular weight chain extenders
with c) organic and/or modified organic polyisocyanates in the
presence of d) catalysts, e) blowing agents, f) adjuvants and/or
additives as well as the polyoxyalkylene polyol mixtures (a).
[0009] The flexible polyurethane foams obtained by this method can
be used in the household sector, for example in back-foaming of
carpets for the dampening of foot fall sound, as interior linings
and in the automotive industry for the dampening of solid-borne
sound, for example for the encapsulation of the motor compartment
or for preventing interior noise by using layers back-foamed with
these foams.
[0010] Carpet backings for the carpets used in the automotive
sector for noise dampening are generally of a stiff structure
because a stepping through or sinking into the carpet is found to
be undesirable.
[0011] When actually using carpets with tangible and therefore
comfort improving dampening properties which comprise a carpet
backing that has been back-foamed with a viscoelastic foam there
are several issues to be taken into consideration. If these carpets
are to be used as floor coverings where persons walk over them and
not only rest their feet as in automobiles, the carpet must be
suitable for bearing the pressure and the shear stress. In
particular, the composite of carpet backing, carpet fibers and back
foam should not disintegrate.
[0012] Finally, it can be observed that walking over a pure layer
of viscoelastic foam which is thick enough to achieve a sufficient
dampening effect is not very comfortable. This can be attributed to
the insecurity that arises when the foot sinks into the foam after
hitting the foam.
[0013] From the preceding it is apparent that the need still exists
for a viscoelastically dampened carpet which displays a high
comfort when one is walking over it, but at the same time stands up
to the stress of use.
SUMMARY OF THE INVENTION
[0014] The present invention has the object of overcoming at least
one of the mentioned drawbacks in the art. In particular, the
invention has the object of providing such a carpet.
[0015] According to the invention this object is achieved by a
floor covering, comprising a first textile planar element and a
first layer which is at least partially connected to the first
textile planar element over their surfaces, wherein the first layer
comprises viscoelastic polymer foam.
[0016] The floor covering according to the invention is
characterized in that the first textile planar element has a
modulus of elasticity of .gtoreq.0.5 N/mm.sup.2 to .ltoreq.2.5
N/mm.sup.2, that in the first layer the viscoelastic polymer foam
has a compression load deflection at 40% compression of .gtoreq.1
kPa to .ltoreq.10 kPa and that in the first layer the viscoelastic
polymer foam has a hysteresis when determining the compression load
deflection at 40% compression of .gtoreq.20% to .ltoreq.70%.
A BRIEF DESCRIPTION OF THE INVENTION
[0017] FIG. 1 shows a floor covering according to the
invention.
[0018] FIG. 2 shows another floor covering according to the
invention.
[0019] FIG. 3 shows another floor covering according to the
invention.
[0020] FIG. 4 shows another floor covering according to the
invention.
A DETAILED DESCRIPTION OF THE INVENTION
[0021] As used herein, the singular terms "a" and "the" are
synonymous and used interchangeably with "one or more."
Accordingly, for example, reference to "a fiber" herein or in the
appended claims can refer to a single fiber or more than one fiber.
Additionally, all numerical values, unless otherwise specifically
noted, are understood to be modified by the word "about."
[0022] In the sense of the present invention a floor covering not
only means carpets, foot mats and the like, but is also to be
understood as seating cushions for furniture or as mattresses.
[0023] The first textile planar element may, for example, be a
woven fabric, a fibrous non-woven layer, a fleece or be knitted.
Additionally, fibers may protrude from the first textile planar
element, so that an assembly corresponding to a carpet backing is
achieved. Furthermore, the textile may also be embedded in a
polymer. The first textile planar element is connected to the first
layer over their surfaces, meaning that the main surfaces of both
are facing each other. In other words, the first textile planar
element and the first layer are stacked on top of each other.
[0024] According to the invention the first textile planar element
has a modulus of elasticity of .gtoreq.0.5 N/mm.sup.2 to
.ltoreq.2.5 N/mm.sup.2. This is to be understood as the modulus of
elasticity for stretching along the direction of the plane of the
planar element. The modulus of elasticity can also be in a range
from .gtoreq.0.8 N/mm.sup.2 to .ltoreq.2.0 N/mm.sup.2 or in a range
from .gtoreq.1.0 N/mm.sup.2 to .ltoreq.1.5 N/mm.sup.2. The modulus
of elasticity is determined using the norm DIN 53504/ISO 37. It may
be provided that the first textile planar element, for example in
the case of a knitted fabric, displays an elasticity of stretching
the fabric and, after further elongation, an elasticity of the
individual threads of the textile. In this case the selected
modulus of elasticity according to the invention means the
elasticity of stretching the fabric.
[0025] The connection has the effect that mechanical forces,
especially shear stress, are transferred from the first textile
planar element to the first layer. The connection can be a
substance-to-substance connection, a force-fitting connection or a
form-fitting connection. Examples for suitable connections are
adhesives, welding, back-foaming of the first textile planar layer
with materials leading to the polymer foam, hook and loop
fasteners, zippers, push buttons and/or sewing.
[0026] The connection may be realized completely or also partially.
A partial connection can be achieved by selectively creating
connection spots or by arranging them in a certain pattern.
[0027] The first layer comprises viscoelastic polymer foam.
Primarily, this means that besides the viscoelastic polymer foam
additional components such as fillers, colorants, etc. may be
present. The polymer foam may have a uniform density or the density
may vary according to the location within the foam such as in
integral foams. Examples for suitable polymer classes are
polyurethane, polyethylene, polypropylene, polystyrene,
acrylonitrile-butadiene-styrene (ABS) and polycarbonate or natural
or synthetic latex. The first layer may have, for example, a
thickness of .gtoreq.10 mm to .ltoreq.60 mm, preferably of
.gtoreq.15 mm to .ltoreq.30 mm.
[0028] The viscoelastic properties of the polymer foam in the first
layer lead to a time-delayed entry of energy into the foam. They
are firstly characterized in that the compression load deflection
at 40% compression is from .gtoreq.1 kPa to .ltoreq.10 kPa. This
compression load deflection can also be in the range of .gtoreq.1.1
kPa to .ltoreq.3 kPa or from .gtoreq.1.2 kPa to .ltoreq.2 kPa.
Furthermore, the viscoelasticity of the polymer foam is
characterized by a hysteresis when determining the compression load
deflection at 40% compression of .gtoreq.20% to .ltoreq.70%. The
hysteresis can also be in a range of .gtoreq.30% to .ltoreq.60% or
from .gtoreq.35% to .ltoreq.50%
[0029] The compression load deflection or CLD is measured according
to DIN EN ISO 3386-1-98 at 23.degree. C..+-.2.degree. C., 50%.+-.5%
relative humidity, 40% compression, 1. measurement cycle. The CLD
is given in kPa (kilopascal). The hysteresis in percent is also
measured according to DIN EN ISO 3386-1-98. It is calculated from
the quotient of the area enclosed between the characteristic curves
for stress and recovery, multiplied by 100. The hysteresis number
gives an information about the ratio of applied and dissipated
energy. Small hysteresis numbers, such as around 5%, indicate
predominantly elastic behavior. Large hysteresis numbers, such as
around 90%, indicate predominantly viscous (plastic) behavior.
[0030] Alternatively, the viscoelastic polymer foam may be
characterized in that the foam has an impact resilience, measured
according to DIN EN ISO 8307, of .gtoreq.1% to .ltoreq.15%. This
impact resilience may also be in a range of .gtoreq.3% to
.ltoreq.10% or from .gtoreq.5% to .ltoreq.9%.
[0031] The viscoelastic polymer foam may also have a density
according to DIN EN ISO 3386-1-98 of .gtoreq.45 kg/m.sup.3 to
.ltoreq.120 kg/m.sup.3, preferably of .gtoreq.50 kg/m.sup.3 to
.ltoreq.70 kg/m.sup.3, a tensile strength according to DIN EN ISO
1798-1-00 of .gtoreq.50 kPa to .ltoreq.90 kPa, an elongation
according to DIN EN ISO 1798-1-00 of .gtoreq.150% to .ltoreq.210%,
a compression set under dry conditions according to DIN EN ISO
1856-2000 of .gtoreq.2% to .ltoreq.5% and a compression set at 75%
compression and 95% humidity according to DIN EN ISO 1856-96 of
.gtoreq.2% to .ltoreq.5%.
[0032] In the present invention the comfortable sensation when
walking over the floor covering is effected by the selected
combination of the elasticity of the first textile planar element
and the viscoelasticity of the polymer foam layer. For further
elucidation it should be envisioned how a person walks over the
floor covering according to the invention. In a first phase the
foot with its heel or the shoe heel is placed on the floor
covering. This is accompanied by a high pressure on the covering.
Due to the elasticity of the first textile planar element this
concentrated load is absorbed. Further into the walking process the
person performs a rolling motion with the foot until the entire
foot stands on the floor covering. This rolling motion is dampened
by the viscoelastic polymer foam of the first layer. Finally, the
foot performs another rolling motion until the ball of the foot or
the tip of the toe are left touching the floor covering. In the
subsequent pushing away motion from the floor the mechanical forces
are dampened or transmitted back, respectively. The end result is a
comfortable feeling when walking, which also does not lead to
tiring due to a too soft floor. The floor covering is also
protected by the elastic first textile planar element so that
particularly the first layer with the polymer foam is not damaged
during walking over it.
[0033] In an embodiment of the present invention the viscoelastic
polymer foam of the first layer is a polyurethane foam.
Polyurethanes are especially suited for the polymer foam layer
according to the invention because their viscoelasticity can be
tuned over a wide range. The monomers of the polyurethane foam can
be selected from the group comprising polyether polyols and/or
polyester polyols or their mixtures and at least difunctional
isocyanates from the groups of aliphatic or aromatic isocyanates
and generally known adjuvants, catalysts and stabilizers. Examples
for this are given in the patent documents already cited or also in
EP 0 331 941 A1.
[0034] In a further embodiment of the present invention the
viscoelastic polymer foam of the first layer is a cross-linked
frothed foam from synthetic or natural latex.
[0035] In a further embodiment of the present invention the
material of the first textile planar element comprises polyurethane
and/or thermoplastic polyurethane.
[0036] In a further embodiment of the present invention the
connection between the first textile planar element and the first
layer is effected by an elastomeric adhesive. According to the
invention especially suitable adhesives are one and two component
polyurethane adhesives. Such one component adhesives comprise
isocyanate containing prepolymers which cure under the influence of
moisture. The corresponding two component adhesives comprise a
polyol component and an isocyanate component and are mixed prior to
application. Preferably the cured adhesive layer has a modulus of
elasticity, determined according to DIN EN ISO 527, of .gtoreq.100
MPa to .ltoreq.1500 MPa, of .gtoreq.300 MPa to .ltoreq.1000 MPa or
of .gtoreq.500 MPa to .ltoreq.800 MPa. Using an elastomeric
adhesive allows for a simple manufacturing of the floor covering
according to the invention from separately available parts.
Additionally, the desired effect according to the invention when
walking over the floor covering is also given due to the
elasticity.
[0037] In a further embodiment of the present invention fibers
penetrate the first textile planar element and into the first layer
and the fibers are anchored in the first layer by an elastomeric
adhesive. These fibers lead to an additional strengthening of the
connection between the first textile planar element and the first
layer. This increases the resilience to shear stresses. Suitable
according to the invention are especially elastomeric one and two
component polyurethane adhesives. The fibers may also protrude
externally from the first textile planar element and constitute the
stepping surface of the floor covering. The fibers may be
incorporated into the first textile planar element by methods such
as tufting.
[0038] In a further embodiment of the present invention the first
layer additionally comprises an embedded second textile planar
element which has a modulus of elasticity of .gtoreq.1000
N/mm.sup.2 to .ltoreq.2000 N/mm.sup.2. This is to be understood as
the modulus of elasticity for stretching along the direction of the
plane of the planar element. The modulus of elasticity is
determined using the norm DIN 53504/ISO 37. It also be in a range
of .gtoreq.1200 N/mm.sup.2 to .ltoreq.1800 N/mm.sup.2 or of
.gtoreq.1400 N/mm.sup.2 to .ltoreq.1600 N/mm.sup.2. The second
textile planar element may, for example, be a woven fabric, a
fibrous non-woven layer, a fleece or be knitted. Advantageously it
is oriented to the first layer with its surface, meaning that the
two major surfaces of second textile planar element and first layer
are facing each other.
[0039] While the second textile planar element, vertically seen,
may in general be located at any height within the first layer, it
is advantageous if it is located at the lower end of the first
layer, towards the floor. The incorporation of a second textile
planar element with elastic properties selected according to the
invention has the effect that the horizontal tearing strength of
the floor covering is increased. Furthermore, the introduction of a
comparatively high horizontal modulus of elasticity serves to
increase the horizontal dimensional stability of the floor
covering. By the positioning at the lower end of the first layer
the influence that the second textile planar element has on the
dampening properties of the other components of the floor covering
is reduced. Therefore, a vertical dampening gradient with the
associated comfortable sensation can still be established while a
person is walking over the floor covering. By way of example, the
second textile planar element may be connected to the first layer
in a form-fitting connection, in a substance-to-substance
connection or it may be integrated into the foam of the first
layer.
[0040] In a further embodiment of the present invention the floor
covering further comprises a second layer arranged on the side of
the first layer which is opposite to the first textile planar
element and which is at least partially, for example via
substance-to-substance, connected to the first layer, wherein the
second layer comprises polymer foam which has a compression load
deflection at 40% compression of .gtoreq.15 kPa to .ltoreq.150 kPa.
A substance-to-substance connection may be realized by an adhesive
or by welding. Suitable according to the invention are elastomeric
one and two component polyurethane adhesives. The second layer may,
for example, have a thickness of .gtoreq.10 mm to .ltoreq.40 mm,
preferred of .gtoreq.15 mm to .ltoreq.30 mm.
[0041] A polymer foam with the above mentioned compression load
deflections may be a flocculated polyurethane foam. The polymer
foam may also have a density according to DIN EN ISO 3386-1-98 of
.gtoreq.60 kg/m.sup.3 to .ltoreq.200 kg/m.sup.3, a tensile strength
according to DIN EN ISO 1798-1-00 of .gtoreq.40 kPa to .ltoreq.150
kPa and an elongation according to DIN EN ISO 1798-1-00 of
.gtoreq.40% to .ltoreq.90%. The high compression load deflections
and restoring forces are employed and a stiffer layer on the floor
side of the floor covering is provided. This has the advantage that
the heel of the foot or of the shoe is supported better when
stepping on the floor covering. The comfort is increased when
walking over the floor covering while at the same time the
thickness of the first layer can be kept low. An additional
advantage is cost savings due to the use of the cheaper flocculated
foam.
[0042] In an embodiment of the above mentioned floor covering
comprising the second layer it further comprises a third textile
planar element which has a modulus of elasticity of .gtoreq.1000
N/mm.sup.2 to .ltoreq.2000 N/mm.sup.2, wherein the third textile
planar element is arranged on the side of the second layer which is
opposite to the first layer and wherein the third textile planar
element is at least partially connected to the second layer. The
mentioned modulus is to be understood as the modulus of elasticity
for stretching along the direction of the plane of the planar
element.
[0043] The modulus of elasticity is also determined using the norm
DIN 53504/ISO 37. It also be in a range of .gtoreq.1200 N/mm.sup.2
to .ltoreq.1800 N/mm.sup.2 or of .gtoreq.1400 N/mm.sup.2 to
.ltoreq.1600 N/mm.sup.2. The third textile planar element may, for
example, be a woven fabric, a fibrous non-woven layer, a fleece or
be knitted.
[0044] It is advantageous if the second layer is located on the
side of the first layer which is opposite to the first textile
planar element and if the second layer is at least partially
connected to the first layer by a substance-to-substance
connection. In this respect, it is also advantageous if the third
textile planar element is located on the side of the second layer
which is opposite to the first layer and if it is at least
partially connected to the second layer.
[0045] Generally speaking, the arrangement of this embodiment has
the advantage that that the horizontal tearing strength of the
floor covering is increased. Furthermore, the introduction of a
comparatively high horizontal modulus of elasticity serves to
increase the horizontal dimensional stability of the floor
covering. By the positioning at the lower end of the second layer
the influence that the third textile planar element has on the
dampening properties of the other components of the floor covering
is reduced. Therefore, a vertical dampening gradient with the
associated comfortable sensation can still be established while a
person is walking over the floor covering. By way of example, the
third textile planar element may be connected to the second layer
in a form-fitting connection or in a substance-to-substance
connection. Additional advantages are cost savings due to the use
of the cheaper flocculated foam.
[0046] In a further embodiment of the present invention the floor
covering further comprises microencapsulated fragrances.
Microencapsulated fragrances in the meaning of the present
invention are substances in pure form, in solution or in mixtures
which stimulate the sense of smell in a person and which are
contained in capsules. The capsules have a maximum dimension of
.gtoreq.1 .mu.m to .ltoreq.1 mm, preferably of .gtoreq.10 .mu.m to
.ltoreq.100 .mu.m. The microencapsulated fragrances may be
incorporated into the first layer, into the first textile planar
element and/or in optionally present fibers which protrude from the
first textile planar element, for example as carpet tufting. In
walking over floor covering according to the invention the capsules
are destroyed and the fragrances are released. This creates a
pleasant sensation in the respective persons and additionally
contributes to the comfortable impression of the floor
covering.
[0047] According to the invention it is encompassed that the
described embodiments may not only exist in isolated form but may
also be freely combined with each other.
[0048] A further aspect of the invention is a method for
manufacturing a floor covering according to the invention,
comprising the step of back-foaming the first textile planar
element with a reaction mixture leading to the polymer foam of the
first layer. By back-foaming a substance-to-substance connection
between the first textile planar element and the first layer is
easily achieved.
[0049] In an embodiment of the method according to the invention
the reaction mixture comprises a polyol and an isocyanate.
Therefore a viscoelastic polyurethane foam is formed during
back-foaming. The monomers of the polyurethane foam may be selected
from the group comprising polyether polyols and/or polyester
polyols or their mixtures and at least difunctional isocyanates
from the groups of aliphatic or aromatic isocyanates, furthermore
conventional adjuvants, catalysts and stabilizers. Examples are
given in the already cited patent documents or also in EP 0 331 941
A1.
[0050] In the method according to the invention it is also possible
that the reaction mixture comprises a prepolymer and water.
Suitable prepolymers are especially obtained on the basis of di- or
polyisocyanates and polyols.
[0051] The present invention is further described with reference to
the following drawings, wherein:
[0052] FIG. 1 shows a floor covering according to the invention.
The first layer 1 comprises a viscoelastic polymer foam. With its
lower side this layer 1 lies on the floor. On top of the layer 1
the first textile planar element 2 is located. A
substance-to-substance connection joins the first layer 1 and the
first textile planar element 2. On the upper side of the floor
covering fibers 3 protrude outwards. The fibers 3 penetrate through
the first textile planar element and extend into the first layer 1
with their lower end. Preferably the fibers are anchored to the
first layer 1 by an elastomeric adhesive (not shown). By this the
fibers cannot be torn out of the floor covering during use.
[0053] FIG. 2 shows another floor covering according to the
invention. Besides the polymer foam, the first layer 1 located
towards the floor now comprises a second textile planar element 2.
Here, this is depicted as a woven fabric. The second textile planar
element 4 is located in the lower end of the first layer 1. There
is a substance-to-substance connection between the first textile
planar element 2 and the first layer 1. Into the first layer 1
fibers 3 are incorporated which cover the surface of the floor
covering. Due to its elasticity, the second textile planar element
can absorb mechanical forces that arise from walking over the floor
covering which are not absorbed or dampened by the first textile
planar element 2 and the layer with viscoelastic polymer 1.
[0054] FIG. 3 shows another floor covering according to the
invention. Beneath the first layer 1 a second layer 5 is located.
This second layer comprises a polymer foam. The polymer foam has a
higher compression load deflection and restoring forces than the
viscoelastic polymer foam of the first layer 1. By this mechanical
forces can be absorbed that arise from walking over the floor
covering which are not absorbed or dampened by the first textile
planar element 2 and the layer with viscoelastic polymer 1.
[0055] FIG. 4 shows another floor covering according to the
invention. Beneath the first layer 1 a second layer 5 is located
and beneath layer 5 a third textile planar element 6. This second
layer 5 comprises a polymer foam. The polymer foam has a higher
compression load deflection and restoring forces than the
viscoelastic polymer foam of the first layer 1. The third textile
planar element 6 comprises a woven fabric. The third textile planar
element 6 and the second layer 5 allow for mechanical forces that
arise from walking over the floor covering to be absorbed which are
not absorbed or dampened by the first textile planar element 2 and
the layer with viscoelastic polymer 1.
LIST OF REFERENCE NUMERALS
[0056] 1 first layer, comprising viscoelastic polymer foam [0057] 2
first textile planar element [0058] 3 fibers [0059] 4 second
textile planar element [0060] 5 second layer, comprising polymer
foam [0061] 6 third textile planar element
[0062] All the references described above are incorporated by
reference in its entirety for all useful purposes.
[0063] While there is shown and described certain specific
structures embodying the invention, it will be manifest to those
skilled in the art that various modifications and rearrangements of
the parts may be made without departing from the spirit and scope
of the underlying inventive concept and that the same is not
limited to the particular forms herein shown and described.
* * * * *