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-9499982-B2
Application number	US-201313907130-A
Country	US
Kind code	B2
Filing date	May 31, 2013
Priority date	Jun 6, 2012
Publication date	Nov 22, 2016
Grant date	Nov 22, 2016

Abstract

The present invention relates to a non-woven fabric made of inorganic fibers, which has a coating of at least two layers on one of both surfaces, wherein
(i) the non-woven fabric made of inorganic fibers has a thickness of at least 0.2 mm, (ii) the first layer of the coating comprises particles, whose particle size is between 50 and 100 μm, (iii) the second layer of the coating, which is applied onto the first layer, comprises particles, wherein more than 90% of the particles have a particle size of less than 20 μm.

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 non-woven fabric made of inorganic fibers, which has a coating of at least two layers on one of both surfaces, wherein
(i) the non-woven fabric made of inorganic fibers has a thickness of at least 0.2 mm, wherein the non-woven fabric fulfills the criteria for A2 or SBI B S1 D0 in a fire test,
(ii) the first layer of the coating comprises a plurality of first particles and a plurality of second particles, wherein:
the first particles have an aspect ratio of more than 100:1,
the first particles are platelet-shaped,
the second particles have a median particle size between 50 and 100 μm,
the first particles comprise calcined clay, and
the second particles comprise calcined clay, and

(iii) the second layer of the coating, which is applied onto the first layer, comprises a plurality of third particles, wherein more than 90% of the third particles have a particle size of less than 20 μm.

2. The non-woven fabric according to claim 1 , wherein the coated non-woven fabric made of inorganic fibers has a weight per unit area of between 100 and 500 g/m 2 , wherein these values refer to the final product, and wherein the coating is at least 25 g/m 2 and at most 300 g/m 2 .

3. The non-woven fabric according to claim 1 , wherein the weight per unit area of the non-woven fabric made of mineral fibers is between 40 and 150 g/m 2 , wherein these data refer to a non-woven fabric with a binder.

4. The non-woven fabric according to claim 1 , wherein the inorganic fibers have an average diameter of between 5 and 30 μm.

5. The non-woven fabric according to claim 1 , wherein the non-woven fabric made of inorganic fibers, in particular of the glass non-woven fabric, is between 10 and 20%, wherein this value refers to the total weight of the non-woven fabric with binder.

6. The non-woven fabric according to claim 1 , wherein the non-woven fabric made of inorganic fibers has a reinforcement, which increases the longitudinal and transverse strengths.

7. The non-woven fabric according to claim 1 , wherein the non-woven fabric made of inorganic fibers has an air permeability in the range of less than 10001/m 2 s prior to coating.

8. The non-woven fabric according to claim 1 , wherein the coated non-woven fabric made of inorganic fibers also has antibacterial, antistatic and/or conductive layers.

9. The non-woven fabric according to claim 1 , wherein the coated non-woven fabric made of inorganic fibers roughness less than 45 μm.

10. The non-woven fabric according to claim 1 , wherein the first layer of the coating has a thickness of between 150 and 500 μm.

11. The non-woven fabric according to claim 1 , wherein the second layer of the coating has a thickness, which is 10%-20%, of the overall thickness of the coating.

12. The non-woven fabric according to claim 1 , wherein an additional, third layer is applied onto the second layer of the coating, wherein this layer comprises a plurality of fourth particles, wherein the fourth particles have a particle size D50 between 2 and 10 μm.

13. The non-woven fabric according to claim 1 , wherein the coating was applied by means of forceless application methods.

14. The non-woven fabric according to claim 1 , wherein the third particles comprise calcium carbonates, calcined clay, titanium dioxide, chalk, color pigments, diatomaceous earth or mixtures of the same.

15. The non-woven fabric according to claim 1 , wherein the outer layer of the coating has at least 10% by weight of titanium dioxide.

16. The non-woven fabric according to claim 1 , wherein the coating comprises chemical binders, wherein the portion of binders in the individual layer is between 20-30% by weight, wherein these values refer to the dry mass of the coating.

17. Printed surfaces containing a printed non-woven fabric wherein the non-woven fabric is defined as in any one of the preceding claims.

18. A printed surface according to claim 17 , wherein the surface is a floor covering, wall covering or ceiling covering.

19. A printed surface according to claim 18 , wherein the surface is a floor covering comprising PVC or cushion vinyl.

20. A printed surface according to claim 18 , wherein the surface is a ceiling covering comprising wood board, engineered wood board, mineral fibers, or plastic boards.

21. A printed surface according to claim 17 , wherein the surface is a floor covering or ceiling covering, which has an adhesive layer, preferably an adhesive layer, which can be activated with water.

22. A printed surface according to claim 17 , wherein the surface has an additional thermoplastic base support or another carrier selected from the group consisting of glass wool boards, cork boards or gypsum boards.

23. A printed surface according to claim 17 , wherein the non-woven fabric is directly printed by digital printing or roller printing.

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

25. The non-woven fabric according to claim 1 , wherein the plurality of second particles have an irregular form.

26. The non-woven fabric according to claim 1 , wherein the plurality of third particles have a particle size D90 that is not greater than 25% of the thickness of the second layer.

27. The non-woven fabric according to claim 1 , wherein the first layer consists of the plurality of first particles, the plurality of second particles, and a binder.

Assignees

• Johns Manville

Inventors

• Ketzer Michael
• Gleich Klaus Friedrich

Classifications

• Y10T428/24372

  Particulate matter · CPC title

• Y10T428/24967

  Absolute thicknesses specified · CPC title

• E04C2/246 Primary

  combinations of materials fully covered by E04C2/16 and E04C2/20 · CPC title

• D06N2209/067

  Flame resistant, fire resistant · CPC title

• D06N2211/06

  Building materials · CPC title