Wall and floor coverings

Abstract

The present invention provides wall and floor coverings based on a carrier coated with one or more layers. The carrier includes a fiberglass containing mat consolidated with a binder, a non-woven made of organic synthetic fibers bonded with the fiberglass containing mat by needling. Part of the organic fibers penetrate through the fiberglass mat, and one or more layers coated on a glass fiber side of said carrier, opposite the non-woven synthetic mat.

1 . Wall and floor coverings based on a carrier coated with one or more layers, said carrier comprising: 
 a fiberglass containing mat consolidated with a binder,    a non-woven made of organic synthetic fibers bounded with said fiberglass mat by needling, wherein part of said organic fibers penetrate through said fiberglass mat; and    one or more layers coated on a glass fiber side of said carrier, opposite the non-woven synthetic mat.    
     
     
         2 . Wall and floor coverings according to  claim 1 , wherein a part of said organic fibers lie adjacent to a side of said fiberglass containing mat that is opposite to said organic fiber non-woven.  
     
     
         3 . Wall and floor coverings according to  claim 1 , wherein said organic fibers are polypropylene fibers.  
     
     
         4 . Wall and floor covering according to  claim 1 , wherein said organic fibers are polyester fibers.  
     
     
         5 . Wall and floor coverings according to  claim 1 , wherein said organic synthetic fibers mat is a fiber staple mat.  
     
     
         6 . Wall and floor coverings according to at least  claim 1 , wherein said organic synthetic fibers mat is a filamentous non-woven.  
     
     
         7 . Wall and floor coverings according to  claim 1 , wherein said fiberglass containing mat is consolidated with a water insoluble binder.  
     
     
         8 . Wall and floor coverings according to  claim 1 , wherein said water insoluble binder is a acrylate copolymer copolymerized with vinyl acetate or styrene, a melamine resin binder or a urea resin binder.  
     
     
         9 . Wall and floor coverings according  claim 1 , wherein said organic synthetic fibers non-woven is pre-consolidated.  
     
     
         10 . Wall and floor coverings according to  claim 9 , wherein said organic synthetic fibers non-woven is hydrodynamically or mechanically pre-consolidated.  
     
     
         11 . Wall and floor coverings according to  claim 9 , wherein said organic synthetic fibers non-woven is thermally pre-consolidated.  
     
     
         12 . Wall and floor coverings according to  claim 1 , wherein said organic synthetic fibers non-woven is thermally fixed (shrunken).  
     
     
         13 . Wall and floor coverings according to  claim 1 , wherein said fiberglass mat includes glass fibers of E, C class, mixture thereof and ECR glass.  
     
     
         14 . Wall and floor coverings according to  claim 1 , wherein said carrier is consolidated with an pure acrylates, copolymers of styrene, butadiene, acrylates and mixtures of duroplastic binders such as urea and melamine binder as a final step.  
     
     
         15 . Wall and floor coverings according to  claim 1 , wherein said fiberglass mat and said organic synthetic fibers non-woven are hydrodynamically or mechanically bonded with each other.  
     
     
         16 . Wall and floor coverings according to  claim 1 , wherein said carrier does not include a binder for final consolidation.  
     
     
         17 . A method for manufacturing wall and floor coverings based on a carrier coated with one or more layers, comprising: 
 providing an organic synthetic fibers or chemical non-woven,    providing a fiberglass containing mat pre-consolidated with a binder, and bonding said mat and non-woven by needling in such that a portion of said organic synthetic fibers penetrate through said fiberglass containing mat and optionally a part of the fibers emerges from the side of synthetic fiber non-woven and lies adjacent thereto; and    coating one or more layers of the glass fiber side of said bonded carrier opposite the non-woven organic mat.    
     
     
         18 . The method according to  claim 17 , wherein said carrier is coated with PVC.  
     
     
         19 . The method according to  claim 17 , wherein said organic fibers are polyester fibers.  
     
     
         20 . The method according to  claim 17 , wherein said organic synthetic fibers are staple fiber mats.  
     
     
         21 . The method according to  claim 17 , wherein said organic synthetic fibers non-woven is a filament non-woven.  
     
     
         22 . The method according to  claim 17 , wherein said glass fiber mat is pre-strengthened by a water insoluble binder.  
     
     
         23 . The method according to  claim 22  wherein said water insoluble binder is a acrylate copolymer, copolymerized with vinyl acetate or styrene.  
     
     
         24 . The method according to  claim 22 , wherein said insoluble binder is a melamine resin or a urea resin.  
     
     
         25 . The method according to  claim 17 , wherein said organic synthetic fibers non-woven is pre-consolidated before bonding with said fiberglass containing mat.  
     
     
         26 . The method according to  claim 25 , wherein said organic synthetic fibers non-woven is hydrodynamically or mechanically pre-consolidated.  
     
     
         27 . The method according to  claim 17 , wherein said organic synthetic fibers non-woven is thermally pre-consolidated.  
     
     
         28 . The method according to  claim 17 , wherein said organic synthetic fibers non-woven is thermally fixed (shrunk).  
     
     
         29 . The method according to  claim 17 , wherein said fiberglass mat includes E, C class fibers, mixtures thereof and ECR glass.  
     
     
         30 . The method according to  claim 17 , further comprising consolidating said carrier with an acrylate or styrene binder after bonding said fiberglass containing mat with said organic synthetic fibers non-woven.  
     
     
         31 . The method according to  claim 17 , wherein said carrier does not include a binder for final consolidation.