Methods to provide a floor covering
A method to provide a floor covering, the steps of: providing a sheet vinyl; a PVC intermediate including at least a first layer of PVC material and at least a first reinforcing sheet, the first layer of PVC material providing the upper side of the PVC intermediate. The method also includes adhering the sheet vinyl to the PVC intermediate by laminating the lower side of the sheet vinyl to the upper side of the PVC intermediate.
1 . A method for manufacturing floor covering elements, said floor covering elements having a rectangular circumference with two pairs of mutually opposing sides, the method comprising:
providing a floor covering at least by extruding a first layer of a PVC intermediate having a density of 1.7 kg/dm 3 or above, calibrating said first layer in thickness by means of a calibration device, subsequently laminating thereto at least a decorative layer and a wear layer contacting said decorative layer and subsequently embossing said wear layer, wherein said first layer comprises a first extruded PVC material, wherein said first extruded PVC material comprises polyvinylchloride or a copolymer of vinylchloride and vinyl acetate, has a Fikentscher K value in the range of 50 to 67, is free from plasticizers or comprises less than 6 phr of plasticizers and comprises at least 30 wt % of fillers;
dividing the floor covering in at least two floor covering elements;
providing said two floor covering elements, at least at a first pair of said two pairs of two mutually opposing sides with coupling means allowing said two floor covering elements to be coupled to each other while locking the sides in a vertical direction perpendicular to the plane of the floor covering elements, where at least one of said sides is provided with a tongue, the opposite side being provided with a groove fit for receiving said tongue.
2 . The method of claim 1 , wherein said fillers are selected from the group consisting of calcium carbonate, talc and microspheres.
3 . The method of claim 2 , wherein said first layer further comprises lubricants and thermal stabilizers.
4 . The method of claim 1 , wherein said calibration device comprise at least a set of calibration rollers.
5 . The method of claim 1 , wherein said embossing is by means of an embossing roller.
6 . The method of claim 1 , wherein said providing a floor covering further comprises extruding at least a second layer of said PVC intermediate.
7 . The method of claim 6 , wherein said second layer is comprised of said first extruded PVC material.
8 . The method of claim 6 , wherein said PVC intermediate further comprises a reinforcing sheet, said reinforcing sheet being a fibrous material.
9 . The method of claim 8 , wherein said first layer and said second layer are extruded at opposite sides of said reinforcing sheet.
10 . The method of claim 6 , wherein said first layer and said second layer are extruded by means of separate extruders.
11 . The method of claim 1 , wherein said first layer is non-foamed or foamed with a density reduction of less than 10% compared to the density of an equal volume of PVC which is free from hollow spaces.
12 . The method of claim 1 , wherein said first layer is mechanically or chemically foamed.
13 . A method for manufacturing floor covering elements, said floor covering elements having a rectangular circumference with two pairs of mutually opposing sides, the method comprising:
providing a floor covering at least by extruding a first layer of a PVC intermediate having a density of 1.7 kg/dm 3 or above, calibrating said first layer in thickness by means of a calibration device, subsequently laminating thereto at least a decorative layer and a wear layer contacting said decorative layer and subsequently embossing said wear layer by means of an embossing roller, wherein said first layer comprises a first extruded PVC material, wherein said first extruded PVC material comprises polyvinylchloride or a copolymer of vinylchloride and vinyl acetate, has a Fikentscher K value in the range of 50 to 67, is free from plasticizers or comprises less than 6 phr of plasticizers and comprises at least 30 wt % of fillers, wherein said fillers are selected from the group consisting of calcium carbonate, talc and microspheres, wherein said first layer is non-foamed or foamed with a density reduction of less than 10% compared to the density of an equal volume of PVC which is free from hollow spaces;
dividing the floor covering in at least two floor covering elements;
providing said two floor covering elements, at least at a first pair of said two pairs of two mutually opposing sides with coupling means allowing said two floor covering elements to be coupled to each other while locking the sides in a vertical direction perpendicular to the plane of the floor covering elements, where at least one of said sides is provided with a tongue, the opposite side being provided with a groove fit for receiving said tongue.
14 . The method of claim 13 , wherein said first layer further comprises lubricants and thermal stabilizers.
15 . The method of claim 13 , wherein said calibration device comprise at least a set of calibration rollers.
16 . The method of claim 13 , wherein said providing a floor covering further comprises extruding at least a second layer of said PVC intermediate, wherein said first layer and said second layer are extruded by means of separate extruders.
17 . The method of claim 16 , wherein said second layer is comprised of said first extruded PVC material.
18 . The method of claim 16 , wherein said second layer is non-foamed or foamed with a density reduction of less than 10% compared to the density of an equal volume of PVC which is free from hollow spaces.
19 . The method of claim 16 , wherein said PVC intermediate further comprises a reinforcing sheet, said reinforcing sheet being a fibrous material, wherein said first layer and said second layer are extruded at opposite sides of said reinforcing sheet.