Coated non-woven fabrics from inorganic fibers and functional, decorative layers for floor coverings, ceiling coverings and wall coverings manufactured therefrom

Patent metadata

Field	Value
Publication number	US-10246818-B2
Application number	US-201615294036-A
Country	US
Kind code	B2
Filing date	Oct 14, 2016
Priority date	Jun 6, 2012
Publication date	Apr 2, 2019
Grant date	Apr 2, 2019

Abstract

The non-woven fabric made of inorganic fibers according to the invention, in particular glass non-woven fabrics, are in particular suitable for producing decorative coatings for floor coverings, ceiling coverings and wall coverings.

First claim

The invention claimed is:

1. A method for the production of a coated non-woven fabric, the method comprising:
supplying a non-woven fabric made of inorganic fibers, the non-woven fabric having a thickness of at least 0.2 mm;
producing a first coating through application of a first suspension comprising a plurality of first particles, the plurality of first particles having a median particle size between 50 and 100 μm; and
producing a second coating onto the first coating through application of a second suspension comprising a plurality of second particles, the plurality of second particles having a particle size D90 smaller than 20 μm;
wherein:
the first coating is produced by means of forceless application methods,
the first suspension comprises a plurality of third particles,
the third particles have an aspect ratio of more than 100:1, and
the third particles are platelet-shaped.

2. The method according to claim 1 , further comprising producing a third coating onto the second coating through application of a third suspension comprising a plurality of fourth particles, the plurality of fourth particles having a particle size D90 between 2 and 10 μm.

3. The method according to claim 1 , wherein:
the non-woven fabric comprises inorganic fibers, and
the non-woven fabric has an air permeability less than 3000 l/m 2 s prior to coating.

4. The method according to claim 1 , wherein:
the non-woven fabric comprises inorganic fibers, and
the non-woven fabric has an air permeability less than 1000 l/m 2 s prior to coating.

5. The method according to claim 1 , wherein the non-woven fabric comprises glass fibers.

6. The method according to claim 1 , wherein the second coating is produced by means of forceless application methods.

7. The method according to claim 1 , further comprising:
drying the first coating and the second coating,
wherein:
during the producing of the first coating and during the producing of the second coating until drying the first coating and the second coating, no increased pressure with respect to the ambient pressure acts on the side of the non-woven fabric to be coated.

8. The method according to claim 1 , wherein:
the first particles comprise calcined clay, and
the third particles comprise calcined clay.

9. The method according to claim 1 , wherein after producing the first coating and producing the second coating, the non-woven fabric has a roughness less than 45 μm.

10. The method according to claim 1 , wherein the first coating has a thickness of between 150 and 500 μm.

11. The method according to claim 1 , wherein the second coating has a thickness from 10% to 20% of the total thickness of coatings on the non-woven fabric.

12. The method according to claim 1 , wherein the second particles comprise calcium carbonates, calcined clay, titanium dioxide, chalk, color pigments, diatomaceous earth, or mixtures of the same.

13. The method according to claim 1 , wherein the first coating and the second coating comprise chemical binders.

14. The method according to claim 1 , wherein the non-woven fabric comprises fibers selected from the group consisting of aluminosilicate fibers, ceramic fibers, dolomite fibers, wollastonite fibers, fibers of vulcanites, and basalt fibers.

15. The method according to claim 1 , wherein the plurality of first particles have an irregular form.

16. The method according to claim 1 , wherein the plurality of second particles have a particle size D90 that is not greater than 25% of the thickness of the second coating.

17. The method according to claim 1 , wherein the coated non-woven fabric has a weight per unit area of between 100 and 500 g/m 2 after producing the second coating, and wherein sum of the first coating and the second coating is at least 25 g/m 2 and at most 300 g/m 2 .

18. The method according to claim 1 , wherein the inorganic fibers have an average diameter of between 5 and 30 μm.

19. The method according to claim 1 , further comprising producing a third coating onto the second coating through application of a third suspension comprising a plurality of fourth particles, the plurality of fourth particles having a median particle size between 2 and 10 μm.

Assignees

• Johns Manville

Inventors

• Ketzer Michael
• Gleich Klaus Friedrich

Classifications

• D06N2203/041

  Polyacrylic · CPC title

• D06N3/0088

  by directly applying the resin (D06N3/0045 takes precedence) · CPC title

• D06N3/0011

  using non-woven fabrics · CPC title

• B05D2203/35

  Glass · CPC title

• D06N3/0063 Primary

  Inorganic compounding ingredients, e.g. metals, carbon fibres, Na2CO3, metal layers; Post-treatment with inorganic compounds · CPC title