Slip-resistant floor coverings

The present invention relates to an improved slip-resistant floor-covering particularly in the form of a luxury vinyl tile and a method for its production.

Slip resistant floors typically use one or more of the following mechanisms to achieve slip resistance:

- a. Inorganic particles (e.g. silicon carbide, aluminium oxide) embedded in the wear layer, protruding to a sufficient extent to provide slip resistance;
- b. A texture which is embossed into the wear layer; and/or
- c. A surface coating on the wear layer, containing particles (e.g. glass, aluminium oxide, polymeric) which provide slip resistance

The inorganic particles have the advantage of being less susceptible to mechanical wear, and therefore provide sustained slip resistance throughout the lifetime of the product (e.g. 20 years). However, they have the disadvantage that they can disrupt the design of the product (e.g. a printed design). Additionally, the inorganic particles cause rapid wear on cutting equipment and any particles present at a cut edge will produce a rough edge (see edges C32 and D32 for the first and second comparative embodiments C30 and D30 illustrated in FIGS. 7 and 8, respectively), either by protruding (illustrated by protruding particle 68 in FIG. 8) or by becoming dislodged and leaving a void (illustrated by partial particle void 66 in FIG. 7). In addition to aesthetic issues, this rough edge can trap dirt and make the product difficult to clean. These difficulties are especially pronounced if the product is cut into tiles, such as in the production of a Luxury Vinyl Tile (LVT).

A way of ameliorating these problems has been sought.

According to the invention there is provided a synthetic slip-resistant floor-covering material comprising a layer of synthetic material which contains one or more degradable polymeric particles wherein the one or more degradable polymeric particles comprise:

- (a) one or more hard degradable polymeric particles which have a hardness which is greater than the hardness of the layer of synthetic material; and optionally
- (b) one or more soft degradable polymeric particles which have a hardness which is the same as or less than the hardness of the layer of synthetic material; and

wherein the one or more hard degradable polymeric particles comprise one or more exposed hard degradable polymeric particles which are exposed at an upper surface of the synthetic floor-covering material to provide slip-resistance.

According to the invention there is further provided a method of preparing a synthetic floor-covering which method comprises the steps of:

- Providing a layer of synthetic material;
- Applying the one or more degradable polymeric particles to the layer of synthetic material; and
- Applying pressure to the layer of synthetic material to ensure that the one or more degradable polymeric particles are incorporated into the layer of synthetic material.

Advantages of the invention include that:

- a. When the product is cut the polymeric particles will also be cut, giving an edge which does not present the problems mentioned previously.
- b. Any polymeric particles which are dislodged from the floor-covering material should not present a microplastics problem as they are degradable. Currently known microplastics problems include marine pollution and plastics entering the food chain.

In some embodiments, the slip-resistant floor-covering material has a surface emboss and/or a layer of slip-resistant particles which are partially embedded in an upper surface of the floor-covering material.

In some embodiments, the degradable polymeric particles may be decomposable without burning or combustion to avoid risk of air pollution. In some embodiments, the degradable polymeric particles may be biodegradable (for example by micro-organisms such as bacteria and/or fungi), oxidatively degradable, UV-degradable, and/or thermally degradable. In some embodiments, a biodegradable polymeric particle may be biodegradable in a bioreactor landfill (as determined by ASTM D5511-12 standard test method), an accelerated landfill (as determined by ASTM D5526-12 standard test method), controlled composting conditions (as determined by ASTM D5338-98e1 standard test method), and/or aerobic composting conditions (as determined by ASTM D6400-12 and/or EN13432 (September 2000)). It should be understood herein that a biodegradable polymeric particle that satisfies ASTM D5511-12 is suitable for anaerobic biodegradation under high-solids anaerobic-digestion conditions; a biodegradable polymeric particle that satisfies ASTM D5526-12 is suitable for anaerobic biodegradation under an accelerated landfill environment where leachate is recirculated back into the landfill; a biodegradable polymeric particle that satisfies ASTM D5338-98e1 is suitable for aerobic biodegradation in an aerobic environment at 60° C.; a biodegradable polymeric particle that satisfies ASTM D6400-12 is suitable for aerobic composting in municipal or industrial facilities within 180 days at a temperature between 55.5° C. and 57° C.

In some embodiments, the one or more polymeric degradable particles may be formed from a polymer which may be pigmented or substantially transparent. In some embodiments, the one or more degradable polymeric particles may be formed from a polymer which has a melting point greater than 120° C. (e.g. greater than 130° C. or greater than 140° C.) such that it retains its shape during the formation of the layer of synthetic material. Typically, such formation may include gelling (e.g. on a gelling drum or in an oven). In an alternative embodiment, the layer of synthetic material comprising the one or more degradable polymeric particles may be formed by laminating such that the melting point of the polymer may be less. In some embodiments, the one or more degradable polymeric particles may be formed from a polyhydroxyalkanoate (e.g. PHA and/or PHB), acrylic copolymer, nylon, and/or a polyester (such as polyglycolic acid, a terephthalate copolymer (such as polyethylene terephthalate and/or polybutylene terephthalate), polycarbonate or polycarbonate copolymer, and/or polylactic acid). In some embodiments, the one or more degradable polymeric particles may comprise one or more different types of different degradable polymeric particles.

In some embodiments, the one or more degradable polymeric particles may be transparent or partially opaque that are not so opaque that they obscure the appearance of any underlying decorative layer. Advantages of using polymeric particles with such a refractive index include that they are substantially transparent, and so would not disrupt the appearance of any printed design layer in the floor-covering material.

In some embodiments, the one or more degradable polymeric particles may have a principal dimension (such as a diameter) of from 15%, e.g. from 20%, e.g. from 25% to 90%, e.g. to 80%, e.g. to 70%, e.g. to 60%, e.g. to 50% of the thickness of the layer of synthetic material.

In some embodiments, the floor-covering material may have a surface emboss to provide a non-slip surface. In some embodiments, the surface emboss may have a maximum depth of from 5 μm, e.g. from 10 μm to 200 μm, e.g. to 150 μm, e.g. to 100 μm.

In some embodiments, the one or more degradable polymeric particles may have a hardness which is the same as or different to a hardness of the layer of synthetic material. In some embodiments, the one or more degradable polymeric particles may comprise one or more hard degradable polymeric particles suitable for use as non-slip particles. In some embodiments, the layer of synthetic material which contains the one or more hard degradable polymeric particles may form an upper layer of the floor-covering covering material or may be exposed as an upper layer of the floor-covering covering material during use. In some embodiments, the one or more hard degradable polymeric particles may have a hardness which is greater than a hardness of a layer of synthetic material in which the hard degradable polymeric particles are placed such that the hard degradable polymeric particles are exposed through wearing of the layer of synthetic material. In some embodiments, the one or more hard degradable polymeric particles may be formed from a polyester (for example polylactic acid and/or polyglycolic acid, a terephthalate copolymer (such as polyethylene terephthalate and/or polybutylene terephthalate), polycarbonate or polycarbonate copolymer) and/or nylon.

It is not straightforward to quantify the difference in hardness between the one or more degradable polymeric particles and the layer of synthetic material because different measurement scales can be used for thermoplastic polymers. Typically, the Shore D hardness scale is used for relatively soft thermoplastic polymers and the Rockwell M hardness scale is used for relatively hard thermoplastic polymers. In some embodiments, the hard polymeric degradable particles may have a hardness which is only quantifiable on the Rockwell M hardness scale and the synthetic material may have a hardness which is only quantifiable on the Shore D hardness scale. In some embodiments, where the hard degradable polymeric particles have a hardness which is quantifiable on the Shore D hardness scale, the hard polymeric degradable particles may have a hardness which is from 2-10 Shore D at 23° C. harder than the Shore D at 23° C. hardness value for the layer of synthetic material, for example about 5 Shore D at 23° C. greater than the Shore D at 23° C. hardness value for the layer of synthetic material. Shore D Hardness is a standardized test consisting in measuring the depth of penetration of a specific indenter. Test methods used to measure Shore D Hardness are ASTM D2240 and ISO 868. The hardness value is determined by the penetration of a Durometer indenter foot into a sample. Shore Hardness measures are dimensionless and may vary from 0 and 100 where a higher number represents a harder material. In some embodiments, the hardness of the hard degradable polymeric particles and of the layer of synthetic material are measured according to ASTM D2240 type D scale at 23° C. (+/−2° C.) and at 50% relative humidity (+/−5%). In some embodiments, the hardness of the hard degradable polymeric particles is measured on the Rockwell hardness M-scale according to ISO2039-2. Advantages of including one or more hard degradable polymeric particles in an upper layer of the floor-covering covering material or is exposed as an upper layer of the floor-covering covering material during use include that the hard degradable polymeric particles are fully embedded in the wear layer and do not affect the maintenance of the product. Only in situations where high product wear is experienced will these particles be exposed through wearing of the layer of synthetic material. Furthermore, the difference in wear resistance between the hard degradable polymeric particles and the wear layer will cause the hard degradable polymeric particles to become exposed, creating surface roughness which produces slip resistance.

In some embodiments, the floor-covering material may have a layer of one or more hard degradable polymeric particles which are partially embedded in an upper surface of the floor-covering material. In some embodiments, the floor-covering material may have a layer of one or more hard degradable polymeric particles which are entirely embedded in a layer of synthetic material.

In some embodiments, the one or more degradable polymeric particles may comprise one or more soft degradable polymeric particles suitable for use as decorative particles. In some embodiments, the one or more soft degradable polymeric particles may have a hardness which is less than the hardness of the layer of synthetic material such that the polymeric particles wear with the layer of synthetic material. In some embodiments, the one or more soft degradable polymeric particles may be formed from polyhydroxyalkanoate (e.g. PHA and/or PHB) and/or an acrylic copolymer. In some embodiments, the soft polymeric degradable particles may have a hardness which is from 2-10 Shore D at 23° C. softer than the Shore D at 23° C. hardness value for the layer of synthetic material, for example about 5 Shore D at 23° C. less than the Shore D at 23° C. hardness value for the layer of synthetic material. In some embodiments, the hardness of the soft degradable polymeric particles and of the layer of synthetic material are measured according to ASTM D2240 type D scale at 23° C. (+/−2° C.) and at 50% relative humidity (+/−5%).

In some embodiments, the floor-covering material may have a layer of one or more soft degradable polymeric particles are entirely embedded in a layer of synthetic material. In some embodiments, the floor-covering material may have one or more soft degradable polymeric particles which may comprise one or more decorative soft degradable polymeric particles.

In some embodiments, the degradable polymeric particles may be formed from polylactic acid (typical Shore D value of about 59 to 77 at 23° C.). In some embodiments, the degradable polymeric particles may be formed from polyglycolic acid (typical Rockwell hardness M-scale of about 105 to 115). In some embodiments, the degradable polymeric particles may be formed from polyacrylic acid (typical Rockwell hardness M-scale of about 70 to 105). In some embodiments, the degradable polymeric particle may be formed from polyethylene terephthalate (typical Shore D value of about 85 to 95 at 23° C.). In some embodiments, the degradable polymeric particle may be formed from polybutylene terephthalate (typical Shore D value of about 90 to 95 at 23° C.). In some embodiments, the degradable polymeric particle may be formed from polycarbonate (typical Shore D value of about 90 to 95 at 23° C.).

In some embodiments, the floor-covering material may comprise a protective coating layer on the layer of synthetic material to form an upper layer of the floor-covering material. In some embodiments, the protective coating layer may comprise a non-slip layer. In some embodiments, the non-slip layer may comprise one or more non-slip particles suitable for providing a non-slip surface wherein such non-slip particles are at least partially embedded in the protective coating layer. In some embodiments, the non-slip particles may comprise one or more hard degradable polymeric particles, one or more inorganic particles (such as aluminium oxide, silicon carbide, quartz and/or glass) and/or one or more organic particles (such as nylon, acrylic, and/or polyurea). In some embodiments, the non-slip particles may have a principle dimension (such as a diameter) of from 3, e.g. from 5, e.g. from 10 to 150 μm, e.g. to 130 μm, e.g. to 110 μm, e.g. to 90 μm. The initial slip resistance will be provided by the surface coating, and optionally by the surface emboss. These can be designed to provide slip resistance and ease of maintenance without detracting from the appearance of the product

In some embodiments, the layer of synthetic material may be formed from a plasticised PVC, polyolefin, polyurethane, an ionomer (such as Dupont Surlyn), EVA, and/or any other flexible polymer. In some embodiments, the layer of synthetic material may be pigmented or may be substantially transparent. Typically, polyvinyl chloride plasticized by about 40 phr of plasticiser has a Shore D value of about 35 to 40 at 23° C., ethylene vinyl acetate has a Shore D value of about 15-45 at 23° C., a polyolefin such as polyethylene has a Shore D value of about 40 to 56 at 23° C. (depending upon the type used), a polyurethane has a Shore D value of about 45 to 60 at 23° C. (depending upon the type used). In some embodiments, the degradable polymeric particles may have a Shore D hardness of from 20, e.g. from 40, e.g. from 45, e.g. to 95, e.g. to 90, e.g. to 85, e.g. to 80, e.g. to 75, e.g. to 70, e.g. to 65 at 23° C.

In some embodiments, the layer of synthetic material and the one or more degradable polymeric particles may be pigmented. In some embodiments, the pigment of the one or more degradable polymeric particles may be the same as that for the layer of synthetic material or may have a different (such as a contrasting) colour.

In some embodiments, the floor-covering material may be a sheet material or a luxury vinyl tile. In some embodiments, floor-covering sheet material may be provided in the form of a roll. In some embodiments, a luxury vinyl tile may comprise a decorative layer and wherein the layer of synthetic material is provided on an upper surface of the decorative layer and wherein the layer of synthetic material is substantially transparent. In some embodiments, the floor-covering material may comprise a lower foamed layer. In some embodiments, the foam layer may include a plurality of layers of synthetic material of which one or more may be foamed to provide comfort to a user. In some embodiments, the floor-covering material may have a substantially smooth cut edge. In some embodiments, the substantially smooth cut edge may be vertical or bevelled such that it is at an angle.

In some embodiments, the layer of synthetic material may include one or more partial polymeric degradable particles. In some embodiments, a partial polymeric degradable particle may be formed by cutting the floor-covering material.

In some embodiments, the layer of synthetic material may have a thickness of from 0.2 mm, e.g. from 0.3 mm, e.g. from 0.5 mm to 2 mm, e.g. to 1.8 mm, e.g. to 1.6 mm, e.g. to 1.4 mm, e.g. to 1.2 mm, e.g. to 1 mm.

In some embodiments, the protective coating layer may comprise a cured polymer layer; suitable polymers for use in the protective coating layer include polyurethane, polyacrylate, urethane acrylate and/or a PVDF based composition. In some embodiments, the protective coating layer may have a thickness of from 5 to 50 μm. In some embodiments, a suitable coating composition for forming a protective coating layer may be a UV curable mixture containing an oligomeric acrylic (which acts as a binder), one or more monomeric acrylics (which acts as a solvent) and a photoinitiator, where each component is cross-linked.

In some embodiments, the synthetic floor-covering material may be provided in the form of a roll or one or more tiles.

In some embodiments, the floor-covering material may be formed from one or more synthetic materials such as a plastics material such as a polymeric material. Suitable plastics materials include PVC, polyvinyl butyral (PVB), polylactic acid (PLA), polyester, a polyolefin, a thermoplastic elastomer and/or polyacrylate.

In some embodiments, the floor-covering material may include one or more of the following layers: a foamed layer, a support layer, a decorative layer, a topcoat layer, a clear wear layer, and/or an external protective coating layer. In some embodiments, the method step of providing a layer of synthetic material may comprise providing one or more of the following layers: a foamed layer, a support layer, a decorative layer, a topcoat layer, a clear wear layer. In some embodiments, the method may comprise the step of: applying a protective coating layer wherein this step is carried out after the step of applying pressure to the layer of synthetic material.

In some embodiments, the floor-covering material may include a support layer. In some embodiments, the support layer may be provided on a lower surface of the layer of synthetic material or on a lower surface of the decorative layer. In some embodiments, the support layer may be an optionally woven layer. In some embodiments, the support layer may be formed from fibres (such as glass fibres, synthetic fibres, or a mix). In some embodiments, the support layer may be a scrim complex. In some embodiments, the support layer may have an impregnated layer of plastics material.

In some embodiments, the floor-covering material may include a decorative layer which may be provided on an upper surface of the support layer (if present). In some embodiments, the decorative layer may comprise a printing layer and a printed design layer.

In some embodiments, the printing layer may be suitable for receiving a printed design or having a printed design applied to it by a digital or gravure printer. In some embodiments, the printing layer may have a pigment which is suitable for providing a background to a printed design where such a pigment may have a similar or contrasting colour to one or more colours in the printed design, e.g. a white pigment. In some embodiments, the printing layer may be formed from a plastics material which may comprise, for example, one or more of the following polymers: PVC, polyvinyl butyral (PVB), polylactic acid (PLA), polyester, a polyolefin, a thermoplastic elastomer and/or polyacrylate.

In some embodiments, the printed design layer may comprise a decoration applied by a printing process, for example offset lithography, flexography, digital printing, gravure, or screen printing. In some embodiments, the printed design layer may be a digitally printed design layer. In some embodiments, the printed design layer may comprise a latex-based ink.

In some embodiments, the decorative layer may be a layer having a decoration such as a pattern. In some embodiments, a decoration or pattern may comprise one or more decorative elements such as a decorative or coloured chip or particle which may be formed from an optionally coloured polymeric or inorganic material.

In some embodiments, the floor-covering material may include a topcoat layer. A topcoat layer may be used as an alternative to a decorative layer. In some embodiments, the topcoat layer may be pigmented. Benefits of including a pigmented topcoat layer include that where the floor-covering material includes a support layer, the pigmented topcoat layer prevents the support layer from being seen. In some embodiments, the topcoat layer may include one or more decorative elements. In some embodiments, the one or more decorative elements may be formed from one or more soft degradable polymeric particles, glass, a ceramic material, an inorganic material (such as aluminium oxide or silicon carbide), and/or a plastics material (such as PVC, polyvinyl butyral (PVB), polylactic acid (PLA), polyester, a polyolefin, a thermoplastic elastomer and/or polyacrylate). In some embodiments, each of the one or more decorative elements may be in the form of a chip having a visible flat surface, a bead or a sphere.

In some embodiments, the foamed layer may comprise a foamed plastics material capable of imparting a sound attenuation effect, for example an acoustic impact sound reduction of more than 10 dB. In some embodiments, the acoustic impact sound absorption may be from 4 dB, e.g. from 6 dB, e.g. from 8 dB, 10 dB, e.g. from 12 dB to 22 dB, e.g. to 20 dB, e.g. to 18 dB, e.g. to 16 dB. In some embodiments, the acoustic impact sound absorption may be 12 dB, 14 dB, 16 dB, or 18 dB. In some embodiments, the foamed plastics material may be mechanically foamed by incorporating one or more types of compressible plastic spheres. In some embodiments, the foamed plastics material may be chemically foamed by an exothermic or endothermic blowing agent. In some embodiments, the blowing agent may be an azodicarbonamide, modified azodicarbonamide, oxy-bis(benzene-suldonylhydrazide), 5-phenyltetrazole, p-Toluylensulfonyl-semicarbazid or p-Toluylensulfonyl-hycarbazide; for example, the blowing agent may be Hydrocerol® (Clariant) or Toamazol™ (Bergen International). In some embodiments, the foamed layer may comprise one or more of the following polymers: PVC, polyvinyl butyral (PVB), polylactic acid (PLA), polyester and/or polyacrylate.

In some embodiments, the floor-covering material may be embossed to provide a decorative finish and/or to improve the non-slip properties of the floor-covering material. In some embodiments, the non-slip layer comprises one or more particles suitable for providing a non-slip surface. In some embodiments, the particles may be at least partially embedded in the floor-covering material. In some embodiments, the particles may comprise one or more aggregate materials. In some embodiments, the particles may comprise one or more types of slip resistant particles such as a glass particle (e.g. a recycled glass bead), a silica particle, a silicon carbide particle, a polymeric particle (for example Nylon (Trademark)), a ceramic particle (e.g. porcelain) and/or an aluminium oxide particle. In some embodiments, the particles may be spherical, semi round, cubical, amorphous, shard shape or have a flake-like construction. In some embodiments, the particles may be smooth particles. A smooth particle is a particle which has no angular protrusion or indentation, for example a particle which has no protrusion or indentation having an outward facing angle of about 90° or less. In some embodiments, the particles may be one or more of a smooth sphere, bead, and/or grain. The advantage of using a smooth particle in the floor-covering material according to the invention is that the cured coating is easier to clean as the coating lacks any angular surface in which a cleaning material (for example the fibres of a mop) may be caught.

The invention will now be described with reference to the following Figures of the accompanying drawings which are not intended to limit the scope of the invention in which:

FIG. 1 shows a schematic cross-section of a first embodiment of a floor-covering material according to the invention;

FIG. 2 shows a schematic cross-section of a second embodiment of a floor-covering material according to the invention;

FIG. 3 shows a schematic cross-section of a third embodiment of a floor-covering material according to the invention;

FIG. 4 shows a schematic cross-section of a fourth embodiment of a floor-covering material according to the invention

FIG. 5 shows a schematic cross-section of a fifth embodiment of a floor-covering material according to the invention in the form of a luxury vinyl tile;

FIG. 6 shows a schematic cross-section of a sixth embodiment of a floor-covering material according to the invention in the form of a tile;

FIG. 7 shows a schematic cross-section of a first comparative embodiment of a floor-covering material which is not according to the invention wherein the first comparative embodiment is in the form of a luxury vinyl tile; and

FIG. 8 shows a schematic cross-section of a second comparative embodiment of a floor-covering material which is not according to the invention wherein the second comparative embodiment is in the form of a tile.

The first embodiment of a floor-covering material according to the invention is indicated generally at 30 on FIG. 1. Floor-covering material 30 comprises a lower layer 32 in the form of a foam-forming plastics material comprising a plasticised PVC composition and an azodicarbonamide, a support layer 33 in the form of a non-woven glass fibre layer arranged on an upper surface of the lower layer 32, an impregnation layer 35 formed of plastics material arranged on an upper surface of the support layer 33, a pigmented printing layer 37 (formed from a pigmented plasticised PVC composition having a white pigment) on an upper surface of the impregnation layer 35, a printed decorative layer 34 on an upper surface of the pigmented printing layer 37, a layer of synthetic material in the form of clear wear layer 36 on an upper surface of the decorative layer 34, and a polyacrylate protective coating layer 38 on an upper surface of the clear wear layer 34. The clear wear layer 36 includes a transparent polymeric particle layer 50 formed from one or more exposed hard transparent degradable polymeric particles 52A which are partially embedded in the wear layer 36 and one or more embedded hard transparent degradable polymeric particles 52B which are entirely embedded in the wear layer 36. Thus, some of the hard transparent degradable polymeric particles 52A,B of the layer of degradable polymeric particles 50 is exposed at the surface of the floor-covering material 30 to provide a non-slip effect. The one or more degradable polymeric particles 52A,B are referred to as being hard as they have a wear resistance which is substantially greater than that of the wear layer 36.

In an alternative embodiment, the lower layer 32 may be mechanically foamed e.g. by incorporation of one or more compressible plastic spheres. In a further alternative embodiment, the hard degradable particles 52A,B may be partially opaque.

The wear layer 36 may be formed from plasticised PVC, polyolefin, polyurethane, ionomers (such as Dupont Surlyn), EVA, or any other flexible polymer that is substantially transparent. The wear layer may have a thickness of from 0.3 mm to 1 mm. The one or more degradable polymeric particles 52A,B may be formed from a polymer which is transparent, is harder than the wear layer, and which has a melting point greater than 140° C. such that it retains its shape during the formation and embossing of the wear layer 36.

Suitable materials for forming the one or more hard degradable polymeric particles 52A,B include a polyester (such as polyglycolic acid, a terephthalate copolymer, a polycarbonate and/or polylactic acid) or nylon. The one or more degradable polymeric particles 52 may be selected to have a principal dimension (such as a diameter) of from 25% to 90% of the thickness of the wear layer 36. The floor-covering material 30 is embossed with a surface emboss (not shown) to provide the floor-covering material 30 with a non-slip surface. The surface emboss has a maximum depth of from 10 to 500 μm. The protective coating layer 38 comprises a cured polymer layer and has a thickness of from 5 to 50 μm.

The printed decorative layer 34 may be applied by any known suitable printing technique such as digital printing or gravure printing on the pigmented printing layer 37. The pigmented printing layer 37 is formulated to be suitable for receiving the printed decorative layer 34. In an alternative embodiment, the pigmented printing layer 37 may be pigmented with a pigment having a colour other than white such as a colour which contrasts or complements the printed decorative layer 34.

Suitable polymers for use in the protective coating layer 38 include polyurethane, polyacrylate, urethane acrylate or a PVDF based composition. A suitable coating composition for forming protective coating layer 38 is a UV curable mixture containing an oligomeric acrylic (the binder), monomeric acrylics (the solvent) and a photoinitiator, where each component is cross-linked.

In an alternative embodiment, the lower layer 32 may be formed from an un-foamed plasticised PVC composition such that lower layer 32 is a compact lower layer 32. In a further alternative embodiment, the one or more transparent degradable polymeric particles 52A,B may be entirely embedded in the wear layer 36 such that they are not exposed at the surface of the floor-covering material 30. As a result of the one or more degradable polymeric particles 52A,B being entirely embedded in the wear layer 36, the maintenance of the floor-covering material 30 is not affected by the one or more degradable polymeric particles 52A,B.

The second embodiment of a floor-covering material according to the invention is indicated generally at 130 on FIG. 2. Like features of the second embodiment to the first embodiment of the floor-covering material are identified by like reference numerals. Floor-covering material 130 comprises the layers of a floor-covering material 30 according to the first embodiment which are the lower layer 32 in the form of a foamed PVC layer, a support layer 33, an impregnation layer 35, a pigmented printing layer 37, a printed decorative layer 34, a layer of synthetic material in the form of wear layer 36 incorporating an embedded particle layer 50B of one or more embedded hard transparent degradable polymeric particles 52B, and a protective coating layer 38. In addition, the protective coating layer 38 comprises a non-slip layer 40. The clear wear layer 36 includes a transparent polymeric particle layer 50 formed from one or more hard transparent degradable polymeric particles 52B which are entirely embedded in the wear layer 36.

Non-slip layer 40 comprises one or more exposed hard transparent degradable polymeric particles 42A and one or more non-slip particles 42D suitable for providing a non-slip surface wherein such non-slip particles 42A,D are at least partially embedded in the protective coating layer 38 and the wear layer 36. The non-slip particles 42D may comprise one or more inorganic particles (such as aluminium oxide, silicon carbide, quartz and/or glass) and/or one or more organic particles (such as nylon, acrylic, and/or polyurea). The non-slip particles 42A,D may have a principal dimension (such as a diameter) of from 5 to 110 μm. The floor-covering material 130 is suitable for use as a covering material for a floor as the non-slip surface is intended to reduce the risk of a person slipping when walking on the floor-covering material. In an alternative embodiment, the non-slip layer 40 of the protective coating layer 38 may only comprise one or more exposed hard transparent degradable polymeric particles 52A.

In situations where high product wear is experienced, the one or more embedded hard degradable polymeric particles 52B will be exposed due to the difference in wear resistance between the one or more embedded hard degradable polymeric particles 52B and the wear layer 36. Exposure of the one or more embedded hard degradable polymeric particles 52B will create surface roughness which produces slip resistance.

In an alternative embodiment, the one or more exposed hard transparent degradable polymeric particles 42A and non-slip particles 42D may be partially embedded only in the protective coating layer 38. In a further alternative embodiment, the embedded particle layer 50B may be a particle layer 50 which comprises in addition to the one or more embedded hard transparent degradable polymeric particles 52B, one or more exposed hard transparent degradable polymeric particles 52A which are partially embedded in the wear layer 36 such that they are exposed at the surface of the floor-covering material 130.

The third embodiment of a floor-covering material according to the invention is indicated generally at 230 on FIG. 3. Like features of the third embodiment to the second embodiment of the floor-covering material are identified by like reference numerals. Floor-covering material 230 comprises the layers of a floor-covering material 130 according to the second embodiment which are the lower layer 32 in the form of a foamed PVC layer, a support layer 33, an impregnation layer 35, a pigmented printing layer 37, a printed decorative layer 34, a layer of synthetic material in the form of wear layer 36 incorporating the embedded particle layer 50B, and a protective coating layer 38 where the protective coating layer 38 comprises a non-slip layer 40. In addition, a fabric backing layer 31 is provided on the lower surface of the lower layer 32. Fabric backing layer 31 is in the form of a fleece layer having an exposed nap suitable for providing sound and/or heat insulation to the floor-covering material 230. The floor-covering material 230 is suitable for use as a covering material for a floor.

The fourth embodiment of a floor-covering material according to the invention is indicated generally at 330 on FIG. 4. Like features of the fourth embodiment to the first, second, and third embodiments of the floor-covering material are identified by like reference numerals. Floor-covering material 330 is a simpler surface-covering which does not include an impregnation layer 35, a pigmented printing layer 37 and a printed decorative layer 34. Instead a pigmented topcoat layer 236 is provided directly on the support layer 33. Floor-covering material 230 comprises a lower layer 232 of synthetic material, a support layer 33 in the form of a scrim complex arranged on an upper surface of the lower layer 232, a layer of synthetic material in the form of pigmented topcoat layer 236 on an upper surface of the support layer 33, a polyacrylate protective coating layer 38 incorporating the non-slip layer 40 on an upper surface of the pigmented topcoat layer 236. The surface-covering 230 incorporates an embedded pigmented particle layer 150B in pigmented topcoat layer 236. The pigmented particle layer 150 includes pigmented hard embedded degradable polymeric particles 152B and pigmented soft embedded degradable polymeric particles 152C. The pigment of the one or more hard embedded degradable polymeric particles 152B and pigmented soft decorative embedded degradable polymeric particles 152C may be the same colour as the pigment for the pigmented topcoat layer 236 or may have a different pigment with a different (such as a contrasting) colour. The pigment of the one or more hard embedded degradable polymeric particles 152B and of the pigmented soft embedded degradable polymeric particles 152C may be the same or different. The lower layer 232 is a compact lower layer 232 as it is not foamed. The pigmented soft embedded degradable polymeric particles 152C may have a hardness which is the same as or less than the hardness of the pigmented topcoat layer 236. The pigmented soft embedded degradable polymeric particles 152C may be formed from a polyhydroxyalkanoate (e.g. PHA and/or PHB) and/or an acrylic copolymer.

In an alternative embodiment, the embedded particle layer 50B may be a particle layer 50 which in addition to the one or more embedded hard transparent degradable polymeric particles 52B, comprises one or more exposed hard transparent degradable polymeric particles 52A which are partially embedded in the wear layer 36 such that they are exposed at the surface of the floor-covering material 130.

The fifth embodiment of a floor-covering material according to the invention is indicated generally at 430 on FIG. 5. Like features of the fourth embodiment 430 to the second embodiment of the floor-covering material 130 are identified by like reference numerals. Floor-covering material 430 is in the form of a luxury vinyl tile and has been cut from the floor-covering material 130 according to the second embodiment of the invention along the vertical line A-A′ indicated on FIG. 2. Floor-covering material 430 comprises the layers of a floor-covering material 130 according to the second embodiment which are the lower layer 32 in the form of a foamed PVC layer, a support layer 33, an impregnation layer 35, a pigmented printing layer 37, a printed decorative layer 34, a layer of synthetic material in the form of wear layer 36, and a protective coating layer 38 which comprises a non-slip layer 40. Vertical line A-A′ cuts through an embedded hard degradable polymeric particle 52, forming a partial embedded hard degradable polymeric particle 254B. The luxury vinyl tile 430 has a vertical substantially smooth cut edge 332. As a result, surface covering material 430 includes an embedded particle layer 250B which comprises one or more transparent embedded hard degradable polymeric particles 2526 and a partial transparent hard embedded degradable polymeric particle 254B. The embedded particle layer 250B is provided in wear layer 36. In an alternative embodiment, cut line A-A′ may be at an angle (e.g. an acute or an oblique angle) such that smooth cut edge 332 is a bevelled edge.

The sixth embodiment of a floor-covering material according to the invention is indicated generally at 530 on FIG. 6. Like features of the sixth embodiment 530 to the fourth embodiment of the floor-covering material 330 are identified by like reference numerals. Floor-covering material 530 is in the form of a tile or a cut piece of floor-covering material and has been cut from the floor-covering material 330 according to the fourth embodiment of the invention along the vertical line B-B′ indicated on FIG. 4. Floor-covering material 430 comprises the layers of a floor-covering material 130 according to the second embodiment which are a lower layer 232 of synthetic material, a support layer 33 in the form of a scrim complex arranged on an upper surface of the lower layer 232, a layer of synthetic material in the form of pigmented topcoat layer 236 on an upper surface of the support layer 33, a polyacrylate protective coating layer 38 incorporating the non-slip layer 40 on an upper surface of the pigmented topcoat layer 236. The floor-covering material 430 incorporates an embedded pigmented particle layer 35013 comprising one or more pigmented embedded hard degradable polymeric particles 3526 and pigmented embedded soft degradable polymeric particles 352C in pigmented topcoat layer 236. Vertical line B-B′ cuts through an embedded pigmented hard degradable polymeric particle 352B, forming a partial embedded hard pigmented degradable polymeric particle 3546 and the luxury vinyl tile 530 has a vertical smooth cut edge 432. As a result, the particle layer 350 comprises a plurality of one or more pigmented embedded hard degradable polymeric particles 352B, one or more pigmented embedded soft degradable polymeric particles 352C and a partial degradable polymeric particle 354B. The embedded particle layer 35013 is provided in topcoat layer 236. In an alternative embodiment, cut line B-B′ may be at an angle such that smooth cut edge 432 is a bevelled edge.

In an alternative embodiment, the pigmented printing layer 37 of floor-covering material 30,130,230,430 may be a foamed pigment printing layer 37 such that the pigment printing layer 37 is formed from a plasticised polymer composition which comprises a foaming or expanding additive and the printed decorative layer 34 may be printed with one or more inks which selectively inhibit the foaming or expanding additive such that the floor-covering material 30,130,230,430 may be chemically embossed.

A first comparative embodiment of a floor-covering material is indicated generally at C30 on FIG. 6. Like features of the first comparative embodiment to the second embodiment of the floor-covering material are identified by like reference numerals. Comparative floor-covering material C30 is in the form of a luxury vinyl tile and has been shown as if cut from a comparative floor-covering material (not shown) along a vertical line (not shown). Comparative floor-covering material C30 comprises the layers of a floor-covering material 330 according to the fourth embodiment which are the lower layer 32 in the form of a foamed PVC layer, a support layer 33, an impregnation layer 35, a pigmented printing layer 37, a printed decorative layer 34, a wear layer 36, and a protective coating layer 38 which comprises a non-slip layer 40. Polymeric particle layer 250 has been replaced by a inorganic particle layer 60 comprising inorganic particles 62. Cutting the tile C30 down the said vertical line dislodged a inorganic particle 62, forming a partial void 66 such that the comparative luxury vinyl tile C30 has a rough cut edge C32. As a result, the inorganic particle layer 60 comprises a plurality of a inorganic particles 62 and a partial void 66. The inorganic particle layer 60 is provided in wear layer 36. In an alternative embodiment, inorganic particle layer 60 may have one or more protruding particles 68 (as illustrated in FIG. 7 for the second comparative embodiment of a floor-covering material D30) at rough cut edge C32.

A second comparative embodiment of a floor-covering material is indicated generally at D30 on FIG. 7. Like features of the first comparative embodiment to the fifth embodiment of the floor-covering material 430 are identified by like reference numerals. Comparative floor-covering material D30 is in the form of a tile or a cut piece of floor-covering material and has been shown as if cut from a comparative floor-covering material (not shown) along a vertical line (not shown). Comparative floor-covering material D30 comprises the layers of a floor-covering material 430 according to the fifth embodiment which are a lower layer 232 of synthetic material, a support layer 33 in the form of a scrim complex arranged on an upper surface of the lower layer 232, a pigmented topcoat layer 236 on an upper surface of the support layer 33, a polyacrylate protective coating layer 38 incorporating the non-slip layer 40 on an upper surface of the pigmented topcoat layer 236. Polymeric particle layer 350 has been replaced by an inorganic particle layer 60. Cutting the tile D30 down the said vertical line dislodged an inorganic particle 62, forming a partial void 66 such that the comparative tile D30 has a rough cut edge D32. As a result, the inorganic particle layer 60 comprises a plurality of inorganic particles 62 and a partial void 66. The inorganic particle layer 60 is provided in wear layer 36.

The floor-covering material 30,130,230,330,430 may optionally be embossed. The floor-covering material 30,130,230 may be provided as a roll of floor-covering material or may optionally be cut up into tiles.

The invention will now be illustrated with reference to the following Examples which are not intended to limit the scope of the claimed invention.

EXAMPLE 1

The method of the invention was performed to prepare a floor-covering material 30,130,230 according to the invention having a printed decorative layer 34 by carrying out the following steps:

- a. coating a non-woven glass fibre with an impregnation layer of plastics material and gelling (the coating) with temperatures higher than 120° C., particularly on a heated drum;
- b. Applying a printing layer formed from a pigmented plasticised PVC composition which may optionally comprise one or more foaming or expanding additives;
- c. gelling the pigmented printing layer on a heated drum;
- d. Printing onto the surface of the pigmented printing layer using gravure printing one or more pigmented inks to form a decorative layer, where the pigmented ink could be transparent or opaque and wherein one or more of the pigmented inks include an inhibitor for the foaming or expanding additive in the printing layer for preparing a chemically embossed floor-covering material;
- e. Drying the printed ink with heat;
- f. Inverting the product;
- g. Applying a backing layer comprising either a foam-forming plastics material comprising a plasticised PVC composition, or a compact-forming plastics material comprising a plasticised PVC composition to form an alternative embodiment to the floor-covering material 30,130,230 where the lower layer is a compact lower layer;
- h. Optionally applying a fleece layer to the backing layer (to form a floor-covering material 230 according to a third embodiment of the invention);
- i. Gelling the backing layer on a heated drum;
- j. Inverting the product;
- k. Applying a wear layer comprising a clear plastics material having a plasticised PVC composition;
- l. Scattering the polymeric material into the surface of the plasticised PVC composition
- m. Gelling the wear layer either on a heated drum or in an oven to form a floor-covering material according to the first embodiment of the invention;
- n. Embossing the wear layer physically, optionally using sufficient temperature and pressure to ensure that at least some of the degradable polymeric particles are entirely incorporated into the wear layer and do not protrude;
- o. Cooling the embossed floor-covering material according to the first embodiment of the invention;
- p. Applying a protective coating layer (optionally containing slip resistant particles to form a surface covering 130 according to the second embodiment of the invention) and curing it to form a floor-covering material according to the second embodiment of the invention;
- q. Winding the product into a roll of the required length; and optionally
- r. Cutting the product into tiles to form a floor-covering material 430 according to the fifth embodiment of the invention or a variant thereof.

EXAMPLE 2

The method of the invention was performed to prepare a floor-covering material 330 according to the fourth embodiment of the invention by carrying out the following steps:

- a. Coating a scrim complex with a lower layer comprising an unfoamed PVC plastisol to form a compact lower layer;
- b. Gelling the plastisol in an oven;
- c. Inverting the product;
- d. Applying a pigmented topcoat layer having a plasticised PVC composition;
- e. Scattering a layer of the degradable polymeric particles into the surface of the plasticised PVC composition
- f. Gelling the pigmented topcoat layer in an oven to form an alternative embodiment of the floor-covering material according to the fourth embodiment of the invention which lacks a protective coating layer;
- g. Embossing the pigmented topcoat layer, optionally using sufficient temperature and pressure to ensure that at least some of the degradable polymeric particles are entirely incorporated into the pigmented topcoat layer and do not protrude;
- h. Cooling the embossed floor-covering material;
- i. Applying a polyacrylate protective coating layer containing slip resistant particles and curing it to form a floor-covering material according to the fourth embodiment of the invention;
- j. Winding the product into a roll of the required length; and optionally
- k. Cutting the product into tiles to form a floor-covering material 530 according to the sixth embodiment of the invention. This may include cuts which are perpendicular to the surface of the flooring (e.g. to cut the product into the shape of the required tile) or cuts at an angle to the surface of the flooring (e.g. to provide a bevelled edge to a tile).

Slip-resistant floor coverings

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