# US 12,180,718 B2 · Dimensionally stable floor covering and method for the production thereof

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- Number: US 12,180,718 B2
- Document ID: US12180718B2
- Status: Granted
- Kind: B2
- Application number: 17/766,791
- Filed: 2020-08-28
- Published: 2024-02-29
- Granted: 2024-12-31
- Earliest claimed: 2019-10-25
- Assignees: Windmöller GmbH
- Applicants: Windmöller GmbH
- Inventors: Ulrich Windmöller; Georg Kruse; Stefan Rose
- Web page: https://patentgrep.com/patent/US12180718B2

## CPC

- B32B 5/024: {Woven fabric}
- E04F 15/107: {composed of several layers, e.g. sandwich panels (layered products in general B32B; producing decorative panels or veneers B44C5/04)}
- B32B 3/26: characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids {(foam layer B32B5/18; layer of synthetic resin characterised by fillers that create voids or cavities B32B27/205); characterised by an apertured layer}
- B32B 3/30: characterised by a layer formed with recesses or projections, e.g. {hollows, grooves, protuberances, ribs (apertured layer B32B3/266; layer with cavities or internal voids B32B3/26)}
- B32B 5/022: {Non-woven fabric}
- B32B 5/026: {Knitted fabric}
- B32B 5/028: {Net structure, e.g. spaced apart filaments bonded at the crossing points}
- B32B 5/245: {another layer next to it being a foam layer}
- B32B 7/14: applied in spaced arrangements, e.g. in stripes
- B32B 27/12: next to a fibrous or filamentary layer
- B32B 27/304: {comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF}
- B32B 27/32: comprising polyolefins {(comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30)}
- B32B 27/36: comprising polyesters
- B32B 27/40: comprising polyurethanes
- E04F 15/105: {of organic plastics with or without reinforcements or filling materials}
- B32B 2250/03: 3 layers
- B32B 2250/04: 4 layers
- B32B 2250/05: 5 or more layers
- B32B 2262/0261: Polyamide fibres
- B32B 2262/0276: Polyester fibres
- B32B 2262/101: Glass fibres
- B32B 2264/1021: Silica
- B32B 2264/104: Oxysalt, e.g. carbonate, sulfate, phosphate or nitrate particles
- B32B 2266/0278: Polyurethane
- B32B 2307/102: Insulating
- B32B 2307/51: Elastic
- B32B 2307/546: Flexural strength; Flexion stiffness
- B32B 2307/734: Dimensional stability
- B32B 2471/00: Floor coverings (B32B2419/04 takes precedence)
- B32B 2471/04: Mats
- E04F 15/02155: {Adhesive means specially adapted therefor, e.g. adhesive foils or strips}
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- E04F: FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS (windows, doors E06B)

## Abstract

A floor covering includes a plastics core, which has an upper side and a lower side, a functional layer and a reinforcement mat arranged on the upper side, and which has fibers and voids located therebetween, wherein the reinforcement mat is located between the upper side of the plastics core and the functional layer, the reinforcement mat and the functional layer constituting a preproduced unit, in which the reinforcement mat is fastened to the functional layer, wherein the plastics core is joined with the preproduced unit in such a way that the plastics core is joined with the fibers of the reinforcement mat and through the voids of the reinforcement mat with the functional layer such that the floor covering has a high degree of dimensional stability, and a method for producing the floor covering.

## Claims

### Claim 1

A floor covering comprising:
a plastics core having an upper side and a lower side, and
a functional layer and reinforcement mat arranged on the upper side, the reinforcement mat having fibers and voids located therebetween,
wherein the reinforcement mat is located between the upper side of the plastics core and the functional layer,
wherein the functional layer comprises a plastics film,
wherein the reinforcement mat and the plastics film constitute a preproduced unit, in which the reinforcement mat is fastened to the plastics film,
wherein the plastics core is joined with the preproduced unit in such a way that the plastics core is joined with the fibers of the reinforcement mat and through the voids of the reinforcement mat with the plastics film,
wherein the reinforcement mat has a binding agent for fixing the fibers,
wherein the binding agent also fastens the reinforcement mat to the plastics film, and
wherein a ratio of a first portion of the area of the functional layer, which is wetted or covered with the binding agent, assumes a value of between 2 and 80% in relation to the overall area of the functional layer such that the voids are defined in a second portion of the functional layer other than the first portion, in relation to the overall area of the functional layer, that is not wetted or covered with the binding agent, and
wherein the fibers of the reinforcement mat are only positioned in the first portion of the area of the plastics film that is wetted or covered with the binding agent.

### Claim 2 (depends on 1)

A floor covering according to claim 1, wherein the plastics film is made of polyester.

### Claim 3 (depends on 2)

A floor covering according to claim 2, wherein the plastics film is made of PET.

### Claim 4 (depends on 1)

A floor covering according to claim 1, wherein the reinforcement mat is a glass fiber mat.

### Claim 5 (depends on 1)

A floor covering according to claim 1, wherein the reinforcement mat comprises one of:
a nonwoven fabric,
a woven fabric,
a knitted fabric or
a scrim.

### Claim 6 (depends on 1)

A floor covering according to claim 1, wherein the plastics core is made of polyurethane.

### Claim 7 (depends on 1)

A floor covering according to claim 1, further comprising at least one further layer provided on a side of the functional layer facing away from the plastics core.

### Claim 8 (depends on 1)

A floor covering according to claim 1, further comprising a rear-sided functional layer arranged on the lower side of the plastics core.

### Claim 9

A method for producing a floor covering, wherein the floor covering has a plastics core with an upper side and a lower side and a functional layer and a reinforcement mat arranged on the upper side, the reinforcement mat having fibers and voids disposed therebetween, wherein the method comprises the following steps:
providing that the functional layer comprises a plastics film,
providing a preproduced unit comprising the plastics film and the reinforcement mat, wherein the reinforcement mat is fastened onto the plastics film;
bonding the preproduced unit to the plastics core such that the reinforcement mat is arranged between the upper side of the plastics core and the plastics film, and such that the plastics core is joined with the reinforcement mat and through the voids of the reinforcement mat to the plastics film;
using a binding agent for:
fixing the fibers of the reinforcement mat and
fastening the reinforcement mat to the plastics film,
wherein a ratio of a first portion of the area of the functional layer which is wetted or covered with the binding agent, assumes a value of between 2 and 80% in relation to the overall area of the functional layer such that the voids are defined in a second portion of the functional layer other than the first portion, in relation to the overall area of the functional layer, that is not wetted or covered with the binding agent, and
positioning the fibers of the reinforcement mat only in the first portion of the area of the plastics film that is wetted or covered with the binding agent.

### Claim 10 (depends on 9)

A method according to claim 9, further comprising the step of joining the reinforcement mat with the functional layer with the assistance of one of:
pressure,
heat input, or
both pressure and heat input.

### Claim 11 (depends on 9)

A method according to claim 9, further comprising the step of placing the reinforcement mat against the functional layer, when the binding agent is in a liquid state.

### Claim 12 (depends on 9)

A method according to claim 9, wherein the reinforcement mat comprises a network of transverse fibers and longitudinal fibers, which are fixed at crossing points thereof.

### Claim 13 (depends on 9)

A method according to claim 9, wherein a plastics material is used for production of the plastics core, and further comprising the step of applying plastics material in a liquid state to the preproduced unit of the functional layer and reinforcement mat, such that the liquid plastics material passes through the voids of the reinforcement mat and thereby forms a connection with the functional layer and the fibers of the reinforcement layer.