EP2694300B1 - Procédé de fabrication d'un revêtement de sol - Google Patents

Procédé de fabrication d'un revêtement de sol Download PDF

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Publication number
EP2694300B1
EP2694300B1 EP12727246.6A EP12727246A EP2694300B1 EP 2694300 B1 EP2694300 B1 EP 2694300B1 EP 12727246 A EP12727246 A EP 12727246A EP 2694300 B1 EP2694300 B1 EP 2694300B1
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EP
European Patent Office
Prior art keywords
layer
floor panel
carrier layer
binder
nonwoven
Prior art date
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Application number
EP12727246.6A
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German (de)
English (en)
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EP2694300A1 (fr
Inventor
Guido Schulte
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Individual
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Individual
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B44—DECORATIVE ARTS
    • B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
    • B44C5/00—Processes for producing special ornamental bodies
    • B44C5/04—Ornamental plaques, e.g. decorative panels, decorative veneers
    • B44C5/0469—Ornamental plaques, e.g. decorative panels, decorative veneers comprising a decorative sheet and a core formed by one or more resin impregnated sheets of paper
    • B44C5/0476—Ornamental plaques, e.g. decorative panels, decorative veneers comprising a decorative sheet and a core formed by one or more resin impregnated sheets of paper with abrasion resistant properties
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/02—Flooring or floor layers composed of a number of similar elements
    • E04F15/10—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials
    • E04F15/107—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials composed of several layers, e.g. sandwich panels

Definitions

  • the invention relates to a method for producing a floor panel.
  • a laminate floor panel consists of a carrier plate of fiber material, usually a high- or medium-compressed fiberboard, on top of which a decorative layer, for example a resinated decor paper, is applied.
  • the decorative layer determines the appearance of the laminate.
  • overlay or the seal forms a special treated wear layer of paint, which gives the floor panel a high surface durability.
  • a return can be applied on the underside of the carrier layer. This serves the dimensional stability and the moisture barrier.
  • a footfall sound insulation can also be provided on the underside.
  • a laminate floor consists of several rows of rectangular floor panels in their configuration.
  • the bottom panel On one longitudinal side and one head side, the bottom panel usually has continuous grooves and, on the respectively opposite longitudinal side or head side, continuous springs which are adapted in a form-fitting manner to the grooves.
  • tongue and groove the floor elements are laid, the floor panel of two adjacent rows is arranged offset from one another.
  • the carrier layer consists of a compressed fiberboard.
  • the fiberboard are very suitable for the purpose. They have the necessary stability, are easy to work with and cost-effective. High density and medium density fiberboards, however, are relatively rigid and stiff and do not conform to the subfloor. There is no thermoplastic flow. This is often good, but sometimes also disadvantageous, especially if a certain elasticity of the floor covering would be desirable due to the laying situation or the substructure.
  • the carrier layer there referred to as the core, made of soft PVC.
  • a decorative film is provided, which is printed with a decor.
  • a transparent wear layer is applied, which also consists of PVC.
  • the state of the art counts by the DE 10 2009 000 717 A1 also a natural / plastic fabric, which can be used, among other things, for the production of floor coverings.
  • the natural / plastic sheet on a carrier layer of compacted To lighten fiber material which are provided with a click system to allow laying similar to a finished parquet.
  • a Bodenpaneel known that has a carrier layer, wherein above the support layer, a decorative layer and an overlay is arranged.
  • the carrier layer is formed on the basis of a mineral material and a binder.
  • DE 199 44 399 A1 discloses a floor panel having a support layer formed on the basis of a mineral material and a binder. Above the carrier layer, a decorative layer and an overlay is arranged.
  • A1 known floor panel consists of the base layer of a biomaterial-plastic composite material. In the carrier layer cavities may be formed.
  • the EP 0 081 147 B1 discloses a building panel consisting of a pressed core of wood particles surrounded by thermoset phenol-formaldehyde resin.
  • a decorative layer is arranged, which may consist of a fabric, nonwoven fabric, a plastic, paper or wood foil and / or a lacquer layer.
  • the carrier layer is provided with a decoration that is covered with a sealing layer. Into the sealing layer is one too embossed surface corresponding structure of the decor.
  • the upper layer has depressions formed at least immediately under the decoration.
  • the DE 10 2009 023 737 A1 describes a composite comprising a backing and a fabric laminated to at least one of the two sides of the backing.
  • the textile fabric has at least one binder before lamination and may optionally be provided with a functional material. Furthermore, the textile fabric is provided with a decoration before lamination by digital printing.
  • WO 2007/065481 A1 includes a floor panel with a layer structure of the prior art, which shows an improved fire protection behavior.
  • a fire-retardant layer is provided in the layer structure.
  • the fire-retardant layer contains non-combustible material, for example a fiber mat.
  • a floor panel known with a carrier layer and a cover layer, wherein the carrier layer consists of a composite material of at least two components, namely mineral fibers and binders.
  • the invention is, starting from the prior art, the object of demonstrating a method for producing an environmentally friendly and without PVC or use of plasticizers and isocyanates deriving floor panel.
  • the carrier layer of the floor panel is formed on the basis of a mineral material and a binder.
  • the mineral material is mixed in powder or granular form with the binder and formed into a carrier layer.
  • the mineral material is free of environmental or health impairing Ingredients. The same applies to the binder.
  • the floor panel has a high environmental friendliness.
  • a nonwoven layer is applied to the carrier layer.
  • the decorative layer is then preferably formed by a decor printed on the nonwoven layer decor.
  • the nonwoven layer can also be provided with a primer before printing.
  • This embodiment is particularly advantageous in terms of impact resistance and elasticity of the floor panel.
  • the fleece also acts as a reinforcement and can be modified for special properties, for example in the antistatic effect. Kevlar or carbon fiber nonwovens can also be used as fleece.
  • the carrier layer is PVC- and plasticizer-free, furthermore free of isocyanates.
  • the mineral material ensures a high impression resistance. By choosing the binder, the panel stiffness can be adjusted.
  • the carrier layer can be processed with modern milling and profiling tools and configured for specific applications.
  • a floor panel produced by the method according to the invention consists of the less brittle mineral carrier layer which is more elastic than fibreboards or gypsum boards and which is provided on the upper side with a decoration and a wear layer.
  • the decor or decorative layer is preferably a nonwoven, in particular a printed nonwoven, the wear layer is preferably made of aminoplastic resins.
  • the binder of the carrier layer is formulated such that it gives the carrier layer and thus the bottom panel a purpose-optimized elasticity.
  • the floor panel is insensitive to water. By combining the materials and the mixing ratio of the carrier layer and the synergistic interaction with the structure of the decorative layer and the wear layer, the floor panel is adjustable in terms of elasticity and deformation properties and water absorption / swelling. Particular importance is attached to the nature of the binder and the amount of binder.
  • the carrier layer contains at least 50% by volume of the mineral material.
  • the carrier layer comprises 70% by volume to 100% by volume, preferably 75% by volume to 90% by volume, of the mineral material portion.
  • the mineral material used is preferably gypsum, limestone or dolomite or a mixture of the abovementioned minerals.
  • the binder content in the carrier layer is greater (>) 10% by volume.
  • the binder content is preferably between 18% by volume and 28% by volume, in particular between 20% by volume and 25% by volume.
  • the binder or binder content is matched to the grain size and grain distribution of the mineral materials and in particular with regard to the desired properties, which should have the floor panel.
  • the binder is a water-based acrylate resin.
  • This is a purely water-based and formaldehyde-free acrylate resin, which is environmentally friendly and brings very good binding properties for the production of carrier layers according to the invention.
  • Another advantageous binder is a polymeric binder, in particular a binder based on vinyl acetate and ethylene copolymers.
  • a biopolymer or a polymer blend is very suitable as a binder.
  • biodegradable polymeric binders are used. This also lends itself in practice to the use of polymer blends, which are a mixture of synthetic and natural polymers.
  • Main component of the polymer blend is a natural polymer of a renewable raw material, such as starch, in a proportion of at least 65%.
  • the carrier layer has a basis weight of greater than or equal to ( ⁇ ) 3.0 kg / m 2 .
  • This relatively high mass occupancy (often referred to as basis weight) ensures a good lying behavior of the floor panel. Due to the choice and the composition of the binder, the carrier layer and thus the entire floor panel receives a plastoelastic lying behavior, causing tensions counteracts the overlay or sealing and minimizes or even eliminates distortion.
  • the preparation of components for the carrier layer can be effected by extrusion.
  • the mineral material and the binder are formed in an extruder into pellets or granules and then processed these granular materials to the carrier layer. This is preferably done on a continuous belt press, a so-called Thermomeltstrom. In principle, however, this is also possible on a CPL (Continuous Pressure Laminate) system or the like.
  • the extrudate production of the carrier layer is used in particular in polymeric binders, in particular in a binder in the form of vinyl acetates.
  • acrylate binders these are admixed with the mineral material and this mixture is then shaped into a carrier layer, for example by applying the pasty, spreadable mixture to a belt system, configuring it and drying it.
  • the carrier layer can contain additives, in particular biological additives, in a proportion of less than ( ⁇ ) 50% by volume. This is particularly intended to the use of aggregates in the form of cork or leather granules and similar biological additives. Also rubber or natural rubber are suitable as an additive.
  • the specific weight of the carrier layer is between 1.5 kg / m 3 and 2.5 kg / m 3 , in particular about 2.0 kg / m 3 .
  • the practical application of the floor panel according to the invention is improved in that the side edges of the floor panel are profiled and provided with locking means in the manner of a click system.
  • the carrier layer of mineral material a has very good profiling.
  • the carrier layer can be processed very well with modern milling and Profilierwerkmaschineen and provided at their side edges with a corresponding profiling including locking means.
  • the decorative layer may consist of a printed decorative paper.
  • a decorative layer of decorative paper is relatively inexpensive.
  • the floor panel is provided with an overlay on the upper side.
  • the overlay is formed on one or more layers and consists of transparent paints and / or transparent resins with optionally wear-increasing additives such as corundum.
  • the incorporation of effect particles into the overlay is also possible.
  • the floor panel below or above the carrier layer can be provided with a stabilizing fabric.
  • a multi-layer body is produced.
  • the multilayer body comprises a carrier layer based on a mineral material and at least one decorative layer and an overlay.
  • a nonwoven layer can be arranged between the carrier layer and the decorative layer.
  • the decorative layer can also be formed by a nonwoven layer printed with a décor.
  • the pressing process is carried out at a temperature between 120 ° C and 200 ° C.
  • the pressure during the pressing process is between 1,500 kPa and 6,000 kPa.
  • the carrier layer of mineral material which is bound by a biological binder, is at least partially or partially elasticized during the pressing process. This increases the connection with the remaining layers of the floor panel. This is particularly advantageous in order to give structures to the floor panel despite a thin overlay. Here, deeper structures than previously customary.
  • the surface structures are pressed into the floor panel or its surface in the manner of a grain and gloss levels.
  • the overlay or the resin which forms the overlay during the pressing process, set flexible, so that the resin during the compression is flowable, distributed like a film and then cured.
  • the decorative layer and / or the nonwoven layer can also be applied to the carrier layer if the carrier layer has not yet completely cured.
  • the production of the carrier layer is involved in this process in the process of manufacturing the floor panel.
  • the mineral materials and the binder are mixed and preferably into large-sized plates, for example in the dimensions of 2.10 m x 2.60 m in a thickness of 4 mm to 12 mm, preferably 5 mm to 6 mm formed.
  • the further layers ie at least the decorative layer, if appropriate the nonwoven layer and the overlay, are applied to the carrier layer and this multilayer structure is then pressed.
  • the carrier layer of mineral material bound by the binder can also be used completely cured for producing a floor panel according to the invention.
  • the further layers are then optionally applied with the addition of fixatives and / or adhesives in the layer structure.
  • the nonwoven fabric is a textile fabric of individual fibers or filaments.
  • the nonwoven layer can be formed, for example, from a glass fleece or polyester. Basically, a combination of glass and polyester is possible.
  • the nonwoven layer may further be made of polyamide or polyethylene terephthalate (abbreviation PET). In addition, a combination of polyamide and polyethylene terephthalate is conceivable.
  • the nonwoven may also contain fibers of different strength, in particular stiffening fibers of Kevlar or carbon may be incorporated into the nonwoven.
  • the nonwoven layer is characterized by a high strength and stability.
  • the nonwoven layer is particularly well suited for receiving the decor.
  • the nonwoven layer consists of endless spun filaments, which are solvent and binder-free processed to nonwoven layer.
  • FIGS. 1 to 5 Corresponding components or component components are in the FIGS. 1 to 5 provided with the same reference numerals.
  • the FIGS. 1 to 5 are technically schematized and not to scale.
  • FIGS. 1 to 5 5 shows five different embodiments of a floor panel 1, 2, 3, 4 and 5 produced according to the invention.
  • Each floor panel 1-5 comprises a carrier layer 6, a decorative layer 7 arranged above the carrier layer 6 and an overlay 8.
  • the carrier layer 6 is formed on the basis of a mineral material and a binder, wherein the carrier layer 6 contains at least 50 vol .-% of the mineral material.
  • the mineral material consists of carbonates such as limestone or dolomite.
  • the mineral material may consist wholly or partly of calcium sulfate, namely gypsum, or anhydride. A mixture of the aforementioned minerals is possible.
  • the mineral material is bound by a formaldehyde-free, PVC-free and plasticizer-free binder.
  • the binder may be a water-based acrylate resin.
  • a polymeric binder in particular a binder based on vinyl acetate and ethylene copolymers or a biopolymer or a polymer blend, can be used to bond the mineral material.
  • the mineral material is added in powder form and / or in granulated form with addition of liquid with the binder and formed into a carrier layer.
  • the carrier layer has a basis weight of greater than or equal to ( ⁇ ) 3.0 kg / m 2 . It is possible to incorporate biogenic aggregates such as cork, leather granules and similar natural products into the carrier layer in a proportion which is less than 50% by volume.
  • the profiling is formed on the carrier layer 6 and comprises at the bottom panel 1 - 4 at a first side edge 9 one of two springs 12, 13 limited first groove 14 and at a second side edge 10 a likewise limited by two springs 15, 16 second groove 17th
  • the first groove 14 is formed in a circular section at least in the upper peripheral region 19 adjacent to the upper side of the panel 18 and opens into the first side edge 9 by way of a rounded bead 21 facing the lower panel 20 on the upper first spring 12 bounding the first groove 14.
  • the third spring 15 has at least one adapted to the domed peripheral portion 19 of the first groove 14 upper spherical surface portion 22 and has a top of the second groove 17 forming, provided subsequent to a rounded lower front portion 23 lower insertion slope 24. This corresponds in terms of their inclination angle to the angle of inclination Top of the opposite of the e rsten side edge 9 recessed frontally rounded second spring thirteenth
  • the carrier layer 6 has strip-like locking means 11.
  • a continuous coupling groove 25 are provided with a bottom-projecting limited resilient latching tongue 26 on the first side edge 9.
  • the locking means 11 is formed by a projecting clutch spring 28.
  • the coupling groove 25 and the clutch spring 28 are contour matched so that they engage in the laying of the floor panel 5 in a floor covering adjacent floor panel 5 latching.
  • the clutch springs 28 engage in the coupling grooves 25.
  • Die Latch 26 slides under the clutch springs 28, wherein the rib 27 engages in the locking groove 29. In this way, the bottom panel 5 along its side edges 10, 11 gap-free and glueless tensile and pressure resistant be added.
  • cavities 30 are provided in the carrier layer.
  • the cavities 30 shown here are embedded within the carrier layer 6 and closed circumferentially. Basically, slot or channel-side cavities may be provided which are open on one side and open into the top or bottom of the carrier layer.
  • the decorative layer 7 may be a printed decorative paper.
  • a nonwoven layer 32 is applied to the carrier layer 6.
  • the decorative layer 7 is preferably printed digitally on the nonwoven layer 32.
  • the overlay 8 forms both the bottom panel 1 and the bottom panel 2 - 5, the top or side seal and consists of transparent paints and / or transparent resins, which may be applied in one or more layers.
  • the upper side relief-like surface structures and gloss levels are pressed into the bottom panel 3.
  • the surface structure is so deep that the overlay 8, the decorative layer 7, the nonwoven layer 32 and the top 31 of the carrier layer 6 are structured.
  • a stabilizing fabric 33 is applied on the underside of the floor panel 3.
  • the floor panel 4 in the embodiment of the FIG. 4 has a stabilizing fabric 34 which is incorporated between the nonwoven layer 32 and the carrier layer 6.
  • the stabilizing fabric 34 as well as the overlay 8, the decorative layer 7 and the top 31 of the support layer 6 are provided with a structure or surface structure.
  • a nonwoven layer 32 is adhered on the upper side of the carrier layer 6 of the bottom panel 5.
  • the nonwoven layer 32 is printed with a decor forming the decorative layer 7.
  • the side seal forms the overlay 8.
  • a multi-layer body 35 is produced which comprises the carrier layer 6, the decorative layer 7 and an overlay 8. Between the carrier layer 6 and the decorative layer 7, the nonwoven layer 32 can be arranged.
  • the decorative layer 7 may also be printed on the nonwoven layer 32.
  • the overlay 8 is formed by melamine resin, which is applied as a film or powder on the decorative layer 7.
  • the multilayer body 35 is then fed to a press and cured by means of heat and pressure.
  • the pressing operation is carried out at a temperature between 120 ° C and 200 ° C and a pressure between 1,500 kPa and 6,000 kPa.
  • the carrier layer 6 is at least partially elasticized, in particular an elastification takes place in an upper-side layer.
  • the pressing process there is an intimate connection of the layers of the multi-layer body 35, wherein in the pressing process in the bottom panel 1 - 5 surface-side structures and / or degrees of gloss are pressed.
  • mineral materials are mixed with binders of the type provided according to the invention and formed into the carrier layer 6.
  • the large-format plate consisting of support layer 6, decorative layer 7, optionally the nonwoven layer 32 and the overlay 8 is present.
  • This large-format plate is then divided into individual floor panels 1 - 5 and to the profiled longitudinal side and head side edges and provided with locking means 11.
  • the floor panel 1 - 5 has a thickness of 4 mm to 12 mm, preferably 5 mm to 6 mm.
  • the single floor panel 1 - 5 is self-laying and needs no bonding to the ground.

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Floor Finish (AREA)

Claims (4)

  1. Procédé de fabrication d'un panneau de sol, un corps multicouche (35) étant fabriqué, lequel comprend une couche porteuse (6) à base d'une matière minérale et d'un agent liant, une couche décorative (7) et un revêtement (8), une couche de non-tissé (32) étant agencée entre la couche porteuse (6) et la couche décorative (7) ou la couche décorative (7) étant une couche de non-tissé (32) imprimée avec un décor, le corps multicouche (35) étant amené à une presse et les couches du corps multicouche (35) étant pressées ensemble dans la presse à une certaine température et avec une certaine pression, caractérisé en ce que l'on utilise comme agent liant une résine acrylique à base aqueuse ou un agent liant polymère et en ce que l'on effectue l'opération de pressage à une température comprise entre 120°C et 200°C et avec une pression comprise entre 1500 kPa et 6000 kPa, la couche porteuse (6) étant au moins partiellement élastifiée lors de l'opération de pressage.
  2. Procédé selon la revendication 1, caractérisé en ce que, lors de l'opération de pressage, des degrés de brillance et/ou des structures surfaciques côté visible étant pressés dans le panneau de sol (1-5).
  3. Procédé selon l'une des revendications 1 ou 2, caractérisé en ce que la couche décorative (7) et/ou la couche de non-tissé (32) sont appliquées sur la couche porteuse (6) lorsque la couche porteuse (6) n'est pas encore complètement durcie.
  4. Procédé selon l'une des revendications 1 à 3, caractérisé en ce que les bords latéraux (9, 10) du panneau de sol (1-5) sont profilés et munis de moyens de verrouillage (11).
EP12727246.6A 2011-04-05 2012-03-30 Procédé de fabrication d'un revêtement de sol Active EP2694300B1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102011001807.7A DE102011001807B4 (de) 2011-04-05 2011-04-05 Bodenpaneel und Verfahren zu deren Herstellung
PCT/DE2012/000338 WO2012136188A1 (fr) 2011-04-05 2012-03-30 Revêtement de sol et procédé de fabrication de ce revêtement

Publications (2)

Publication Number Publication Date
EP2694300A1 EP2694300A1 (fr) 2014-02-12
EP2694300B1 true EP2694300B1 (fr) 2016-05-18

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EP12727246.6A Active EP2694300B1 (fr) 2011-04-05 2012-03-30 Procédé de fabrication d'un revêtement de sol

Country Status (4)

Country Link
EP (1) EP2694300B1 (fr)
DE (1) DE102011001807B4 (fr)
PL (1) PL2694300T3 (fr)
WO (1) WO2012136188A1 (fr)

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EP2762328B1 (fr) * 2013-01-30 2015-11-25 Flooring Technologies Ltd. Procédé de fabrication d'un panneau en bois décoré revêtu de chaque côté
TR201812933T4 (tr) * 2013-07-22 2018-09-21 Akzenta Paneele Profile Gmbh Dekore edilmiş bir duvar veya zemin panelinin üretimi için yöntem.
EP2829415A1 (fr) * 2013-07-22 2015-01-28 Akzenta Paneele + Profile GmbH Procédé de fabrication d'un panneau mural et de sol décoré
PL2857221T3 (pl) * 2013-10-07 2018-12-31 Flooring Technologies Ltd. Panel z super matową powierzchnią
DE102013222605A1 (de) * 2013-11-07 2015-05-07 Bernhard ter Hürne Mehrschichtiges Fußbodenpaneel
EP2942208A1 (fr) * 2014-05-09 2015-11-11 Akzenta Paneele + Profile GmbH Procédé de fabrication d'un panneau mural ou de sol décoré
WO2016156506A1 (fr) * 2015-03-31 2016-10-06 Tarkett Gdl S.A. Élément pour revêtement de surface synthétique minéral
DE102018005878A1 (de) * 2018-07-26 2020-01-30 Interprint Gmbh Verwendung eines mehrlagigen Schichtaufbaus
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Also Published As

Publication number Publication date
DE102011001807A1 (de) 2012-10-11
EP2694300A1 (fr) 2014-02-12
DE102011001807B4 (de) 2024-02-08
WO2012136188A1 (fr) 2012-10-11
PL2694300T3 (pl) 2016-12-30

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