Water-permeable floor covering boards

Claim 2

A process for producing in a single molding operation water-permeable, uniformly dimensioned elastic floor covering boards having a resilient, water-permeable backing layer of adhesively bonded rubber particles, and a water-permeable surface layer of adhesively bonded synthetic fibers, said layers being firmly bonded together, comprising the steps of a. depositing in a mold a layer of non-woven synthetic fibers, b. impregnating said layer of synthetic fibers with a resilient polyurethane adhesive, c. depositing on top of said layer of adhesive-impregnated synthetic fibers a layer of natural or synthetic rubber particles having a particle size of between 0.2 and 4.0 cm., said particles being impregnated with a resilient polyurethane adhesive, d. incorporating a foaming agent for said adhesive, e. closing said mold, and f. subjecting said layers in the closed mold to a temperature between room temperature and 100°C. and to a pressure between about 40 and about 100 metric tons per square meter for a period of time sufficient to effect curing of said adhesive, whereby a foamed adhesive matrix is produced in said floor covering boards.

Claim 3

The process as defined by claim 1, wherein said layer of non-woven synthetic fibers is a pre-formed web or felt of said synthetic fibers.

Claim 4

The process as defined by claim 1, wherein said layer of non-woven synthetic fibers comprises a loose layer of felt-forming synthetic fibers.

Claim 5

The process as defined by claim 1, wherein said synthetic fibers are selected from the group consisting of polyamide, polyester, polyacrylonitrile and polyolefin fibers.

Claim 6

The process as defined by claim 1, wherein said foaming agent comprises water.

Claim 7

The process as defined by claim 1, further comprising the step of placing on top of said adhesive-impregnated layer of synthetic fibers a reinforcing layer comprising a woven fiber web.

Claim 8

The process as defined by claim 6, wherein said reinforcing layer comprises a web of woven glass fibers.

Claim 9

The process as defined by claim 1, further comprising the step of providing a plurality of spaced drainage apertures in the resilient backing layer of adhesively bonded rubber particles concurrently with said molding step.

Claim 10

A water-permeable, elastic floor covering board having a resilient, water-permeable backing layer of adhesively bonded rubber particles and a water-permeable surface layer of adhesively bonded synthetic fibers, said floor covering board having been produced by the process defined by claim 1.

Claim 11

A water-permeable, elastic floor covering board having a resilient, water-permeable backing layer of adhesively bonded rubber particles and a water-permeable surface layer of adhesively bonded synthetic fibers, said floor covering board having been produced by the process defined by claim 6.

Claim 12

A process for producing in a single molding operation water-permeable, uniformly dimensioned elastic floor covering boards having a resilient, water-permeable backing layer of adhesively bonded rubber particles, and a water-permeable surface layer of adhesively bonded synthetic fibers, said layers being firmly bonded together, comprising the steps of a. depositing in a mold a layer of non-woven synthetic fibers, b. impregnating said layer of synthetic fibers with a resilient polyurethane adhesive, c. depositing on top of said layer of adhesive-impregnated synthetic fibers a layer of natural or synthetic rubber particles having a particle size of between 0.2 and 4.0 cm., said particles being impregnated with a resilient polyurethane adhesive, c 1 . depositing on top of said layer of impregnated rubber particles a third layer comprising a layer of non-woven synthetic textile fibers, c 2 . impregnating said third layer with a resilient polyurethane adhesive, d. incorporating a foaming agent for said adhesive, e. closing said mold, f. subjecting said layers in the closed mold to a temperature between room temperature and 100°C. and to a pressure between about 40 and about 100 metric tons per square meter for a period of time sufficient to effect curing of said adhesive, whereby a foamed adhesive matrix is produced in said floor covering boards, and g. cutting the resulting layer structure through and in the plane of the layer of adhesively bonded rubber particles parallel to the principal exterior surfaces of the board structure, whereby there is produced two floor covering boards, each having a covering layer of non-woven fibers and a water-permeable backing layer of adhesively bonded rubber particles.

Claim 13

A process for producing in a single molding operation water-permeable, uniformly dimensioned elastic floor covering boards having a resilient, water-permeable backing layer of adhesively bonded rubber particles, and a water-permeable surface layer of adhesively bonded synthetic fibers, said layers being firmly bonded together, comprising the steps of a. depositing in a mold a layer of non-woven synthetic fibers, b. impregnating said layer of synthetic fibers with a resilient polyurethane adhesive, c. depositing on top of said layer of adhesive-impregnated synthetic fibers a layer of natural or synthetic rubber particles having a particle size of between 0.2 and 4.0 cm., said particles being impregnated with a resilient polyurethane adhesive, c 1 . depositing on top of said layer of impregnated rubber particles a third layer comprising a layer of non-woven synthetic textile fibers, c 2 . impregnating said third layer with a resilient polyurethane adhesive, d. incorporating a foaming agent for said adhesive, e. closing said mold, f. subjecting said layers in the closed mold to a temperature between room temperature and 100°C. and to a pressure between about 40 and about 100 metric tons per square meter for a period of time sufficient to effect curing of said adhesive, whereby a foamed adhesive matrix is produced in said floor covering boards, and g. cutting the resulting layer structure through and in the plane of the layer of adhesively bonded rubber particles parallel to the principal exterior surfaces of the board structure, whereby there is produced two floor covering boards, each having a covering layer of non-woven fibers and a water-permeable backing layer of adhesively bonded rubber particles.

Claim 14

A process for producing in a single molding operation water-permeable, uniformly dimensioned elastic floor covering boards having a resilient, water-permeable backing layer of adhesively bonded rubber particles, and a water-permeable surface layer of adhesively bonded synthetic fibers, said layers being firmly bonded together, comprising the steps of a. depositing in a mold a layer of non-woven synthetic fibers, b. impregnating said layer of synthetic fibers with a resilient polyurethane adhesive, b 1 . placing on top of said adhesive-impregnated layer of synthetic fibers a reinforcing layer comprising a woven fiber web, c. depositing on top of said layer of woven fiber web a layer of natural or synthetic rubber particles having a particle size of between 0.2 and 4.0 cm., said particles being impregnated with a resilient polyurethane adhesive, c 1 . depositing on top of said layer of impregnated rubber particles a second reinforcing layer comprising a woven fiber web, c 2 . depositing on top of said second reinforcing layer a fifth layer comprising a layer of non-woven synthetic textile fibers, c 3 . impregnating said fifth layer with a resilient polyurethane adhesive, d. incorporating a foaming agent for said adhesive, e. closing said mold, f. subjecting said layers in the closed mold to a temperature between room temperature and 100°C. and to a pressure between about 40 and about 100 metric tons per square meter for a period of time sufficient to effect curing of said adhesive, whereby a formed adhesive matrix is produced in said floor covering boards, and g. cutting the resulting five-layer structure through and in the plane of the layer of adhesively bonded rubber particles parallel to the principle exterior surfaces of the board structure, whereby there is produced two floor covering boards, each having a covering layer of non-woven fibers, a woven web reinforcing layer and a water-permeable backing layer of adhesively bonded rubber particles.

Claim 15

A process for producing in a single molding operation water-permeable, uniformly dimensioned elastic floor covering boards having a resilient, water-permeable backing layer of adhesively bonded rubber particles, and a water-permeable surface layer of adhesively bonded synthetic fibers, said layers being firmly bonded together, comprising the steps of a. depositing in a mold a layer of non-woven synthetic fibers, b. impregnating said layer of synthetic fibers with a resilient polyurethane adhesive, b 1 . placing on top of said adhesive-impregnated layer of synthetic fibers a reinforcing layer comprising a woven fiber web, c. depositing on top of said layer of woven fiber web a layer of natural or synthetic rubber particles having a particle size of between 0.2 and 4.0 cm., said particles being impregnated with a resilient polyurethane adhesive, c 1 . depositing on top of said layer of impregnated rubber particles a second reinforcing layer comprising a woven fiber web, c 2 . depositing on top of said second reinforcing layer a fifth layer comprising a layer of non-woven synthetic textile fibers, c 3 . impregnating said fifth layer with a resilient polyurethane adhesive, d. incorporating a foaming agent for said adhesive, e. closing said mold, f. subjecting said layers in the closed mold to a temperature between room temperature and 100°C. and to a pressure between about 40 and about 100 metric tons per square meter for a period of time sufficient to effect curing of said adhesive, whereby a formed adhesive matrix is produced in said floor covering boards, and g. cutting the resulting five-layer structure through and in the plane of the layer of adhesively bonded rubber particles parallel to the principle exterior surfaces of the board structure, whereby there is produced two floor covering boards, each having a covering layer of non-woven fibers, a woven web reinforcing layer and a water-permeable backing layer of adhesively bonded rubber particles.