Method to produce a surface covering

Abstract

The present invention relates to a method to produce a polymeric sheet comprising the steps of providing an acid-based polymer, providing a neutralizing agent, the neutralizing agent being selected from the group consisting of an organic metallic compound, a metallic salt of a fatty acid, and an ionomer, or a mixture thereof, providing a processing oil, mixing said acid-based polymer, said neutralizing agent, said processing oil, to obtain a polymeric composition, and processing said polymeric composition to form a polymeric sheet. The polymeric sheet may be used as a component, or as a substrate, of a surface covering. The polymeric sheet may also be used to form polymeric particles which are component of so-called “homogenous”, or substrate-free, surface covering.

1 . A method to produce a polymeric surface covering, said method comprising the steps of:
 providing an acid-based polymer;   providing a neutralizing agent selected from the group consisting of an organic metallic compound, a metallic salt of a fatty acid, and a terpolymer ionomer, or a mixture thereof;   providing a processing additive;   mixing said acid-based polymer, said neutralizing agent and said processing additive, to obtain a polymeric composition;   processing said polymeric composition to form a polymeric sheet;   granulating said polymeric sheet into polymeric particles;   depositing said polymeric particles directly on a band-shape moving carrier of a belt press device;   heating the polymeric particles on said band-shape moving carrier;   pressing under heat the polymeric particles to form said polymeric surface covering.   
     
     
         2 . The method according to  claim 1 , wherein the organic metallic compound is selected from the group consisting of potassium hydroxide, aluminum hydroxide, calcium hydroxide, and zinc oxide, or a mixture thereof. 
     
     
         3 . The method according to  claim 1 , wherein the metallic salt of a fatty acid has between 8 and 28 atoms of carbon. 
     
     
         4 . The method according to  claim 1 , wherein the terpolymer ionomer is of ethylene, butylacrylate and methacrylic acid. 
     
     
         5 . The method according to  claim 1 , wherein the neutralizing agent is a mixture comprising a metallic salt of a fatty acid having between 8 and 28 atoms of carbon and an ionomer. 
     
     
         6 . The method according to  claim 1 , wherein the processing additive is a mineral oil, a vegetable oil or a synthetic oil. 
     
     
         7 . The method according to  claim 1 , wherein the processing additive is selected from the group consisting of citrates, cyclohexane diesters, benzoates, adipates, phosphonates, polyethylene glycols, sunflower oil, linseed oil, and derivatives of castor oil, or a mixture thereof. 
     
     
         8 . The method according to  claim 1 , wherein the acid-based polymer is an ethylene-co-acrylic acid polymer (EAA) or an ethylene-co-methacrylic acid polymer (EMAA). 
     
     
         9 . The method according to  claim 1 , further comprising the steps of providing an additive selected from the group consisting of a filler, a release agent, and a pigment, or a mixture thereof, and introducing said additive in the mixing step. 
     
     
         10 . The method according to  claim 1 , wherein the processing of the polymeric composition, to form a polymeric sheet, is performed by calendering or by extrusion. 
     
     
         11 . The method according to  claim 1 , further comprising the steps of:
 sanding the back of said polymeric surface covering;   mechanically embossing the top of said surface covering;   coating the top of said surface covering with a varnish layer.   
     
     
         12 . The method according to  claim 1 , further comprising the steps of:
 cutting the polymeric surface covering into tiles, and   annealing said tiles.   
     
     
         13 . The method according to  claim 1 , wherein the surface covering is a floor covering. 
     
     
         14 . The method according to  claim 1 , further comprising the stop of removing the polymeric surface covering from the band-shape moving carrier of the belt press device. 
     
     
         15 . A method to produce a polymeric surface covering, said method comprising the steps:
 providing an acid-based polymer, said acid-based polymer being a resin having a melt flow index, measured at 190° C. under 2.16 kg load, of between 10 and 60 g/10 min;   providing a neutralizing agent selected from the group consisting of an organic metallic compound, a metallic salt of a fatty acid, and an ionomer, or a mixture thereof;   providing a processing additive;   mixing said acid-based polymer, said neutralizing agent and said processing additive, to obtain a polymeric composition;   processing said polymeric composition to form a polymeric sheet;   granulating said polymeric sheet into polymeric particles;   depositing said polymeric particles directly on a band-shape moving carrier of a belt press device;   heating the polymeric particles on said band-shape moving carrier;   pressing under heat the polymeric particles to form the polymeric surface covering.   
     
     
         16 . A method to produce a polymeric sheet for a surface covering, said method comprising the steps:
 providing an acid-based polymer, said acid-based polymer being a resin having a melt flow index, measured at 190° C. under 2.16 kg load, of between 10 and 60 g/10 min;   providing a neutralizing agent selected from the group consisting of an organic metallic compound, a metallic salt of a fatty acid, and an ionomer, or a mixture thereof;   providing a processing additive;   mixing said acid-based polymer, said neutralizing agent and said processing additive, to obtain a polymeric composition;   processing said polymeric composition to form the polymeric sheet.