EP3686029B1 - Procédé de fabrication d'un panneau multicouche résistant à l'abrasion et à l'eau - Google Patents

Procédé de fabrication d'un panneau multicouche résistant à l'abrasion et à l'eau Download PDF

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Publication number
EP3686029B1
EP3686029B1 EP19153171.4A EP19153171A EP3686029B1 EP 3686029 B1 EP3686029 B1 EP 3686029B1 EP 19153171 A EP19153171 A EP 19153171A EP 3686029 B1 EP3686029 B1 EP 3686029B1
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EP
European Patent Office
Prior art keywords
layer
applying
abrasion
melt adhesive
polyurethane hot
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Active
Application number
EP19153171.4A
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German (de)
English (en)
Other versions
EP3686029A1 (fr
Inventor
Ingo Lehnhoff
Norbert Kalwa
Frank Oldorff
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Flooring Technologies Ltd
Original Assignee
Flooring Technologies Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority to PT191531714T priority Critical patent/PT3686029T/pt
Application filed by Flooring Technologies Ltd filed Critical Flooring Technologies Ltd
Priority to ES19153171T priority patent/ES2916708T3/es
Priority to PL19153171.4T priority patent/PL3686029T3/pl
Priority to EP19153171.4A priority patent/EP3686029B1/fr
Priority to US17/425,103 priority patent/US12311404B2/en
Priority to CN202080010254.5A priority patent/CN113348094A/zh
Priority to PCT/EP2020/050436 priority patent/WO2020151956A1/fr
Publication of EP3686029A1 publication Critical patent/EP3686029A1/fr
Application granted granted Critical
Publication of EP3686029B1 publication Critical patent/EP3686029B1/fr
Active legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D1/00—Processes for applying liquids or other fluent materials
    • B05D1/36—Successively applying liquids or other fluent materials, e.g. without intermediate treatment
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D1/00—Processes for applying liquids or other fluent materials
    • B05D1/28—Processes for applying liquids or other fluent materials performed by transfer from the surfaces of elements carrying the liquid or other fluent material, e.g. brushes, pads, rollers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D3/00—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials
    • B05D3/12—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by mechanical means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D5/00—Processes for applying liquids or other fluent materials to surfaces to obtain special surface effects, finishes or structures
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D7/00—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials
    • B05D7/50—Multilayers
    • B05D7/51—One specific pretreatment, e.g. phosphatation, chromatation, in combination with one specific coating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D7/00—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials
    • B05D7/50—Multilayers
    • B05D7/56—Three layers or more
    • B05D7/57—Three layers or more the last layer being a clear coat
    • B05D7/572—Three layers or more the last layer being a clear coat all layers being cured or baked together
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D2201/00—Polymeric substrate or laminate
    • B05D2201/02—Polymeric substrate
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D2252/00—Sheets
    • B05D2252/04—Sheets of definite length in a continuous process
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D2350/00—Pretreatment of the substrate
    • B05D2350/30—Change of the surface
    • B05D2350/33—Roughening
    • B05D2350/38—Roughening by mechanical means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D2503/00—Polyurethanes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D2601/00—Inorganic fillers
    • B05D2601/20—Inorganic fillers used for non-pigmentation effect

Definitions

  • the present invention relates to a method for manufacturing an abrasion-resistant and waterproof multi-layer panel and a production line for carrying out this method.
  • PVC floor coverings are often preferred in public and commercial places, but also in the home due to its durable properties, easy installation and low cost.
  • Floor coverings based on PVC are divided into several categories and subcategories. A distinction is made in particular between traditional PVC coverings and the so-called LVT (Luxury Vinyl Tile) coverings.
  • Traditional PVC flooring essentially uses PVC as the base material with plasticizers, resulting in a flexible product that can be easily printed and laid on a floor.
  • Traditional PVC products are among the most cost-effective floor coverings currently available.
  • WPC wood plastic composites or waterproof plastic composites
  • the multi-layer PVC floor coverings include the SPC coverings, the core of which consists of a plastic component (usually PVC) and a larger proportion of minerals. Due to the higher mineral content, the stiffness, weight and density is higher.
  • SPC stone plastic composite
  • the carrier consists of a highly filled thermoplastic material, such as polyvinyl chloride or polypropylene, with chalk or talc usually being used as fillers.
  • the decorative layer is usually a printed, thermoplastic foil, which also has PVC or PP as the material basis.
  • the wear layer is a transparent, thermoplastic film (PVC or PP).
  • the backing is first produced in an extruder and immediately afterwards the decorative and wear-resistant foil are calendered on.
  • the surface structure of the product is created by the structuring of the calender.
  • the present invention is therefore based on the technical task of providing a method for producing an SPC floor covering, in which the surface of the plastic carrier board is produced and finished more efficiently.
  • the technical properties should not deteriorate and no other product deterioration should occur.
  • the productivity of the production line should also not be impaired by the process.
  • the production of the plastic support plate can precede the above method.
  • the plastic carrier board is initially provided as an endless strand and, if necessary, then cut to size.
  • the plastic carrier plate (or the SPC core) consists of polyvinyl chloride (PVC), but can consist of various thermoplastics (PVC) or polypropylene (PP),
  • the plastic carrier board is first produced as a continuous strand by extrusion of a mixture containing PVC, limestone and optional auxiliaries.
  • the mixture to be extruded can be provided in various alternatives.
  • the mixture to be extruded can be presented in the form of a powder, with the various ingredients being mixed in a mixing device to form a powdery mixture which, after optional intermediate storage, is introduced into the extruding device.
  • the mixture is provided in the form of a compound.
  • the compound consists of the individual components that have already been melted together and are then crushed into processable particles (e.g. pellets) that are fed into the extruder device. Accordingly, when using a compound, there is no need for a mixing device, intermediate bunker and melting device.
  • the mixture to be extruded consists of 20-40% by weight PVC, preferably 25-35% by weight PVC, 60-80% by weight limestone, preferably 65-75% by weight limestone and optionally further auxiliary substances.
  • the mixture to be extruded comprises 65% by weight limestone (chalk) and 35% by weight PVC.
  • the grain size of limestone should be similar to the grain size of PVC powder. This simplifies the production of the powder mixture and avoids demixing or inhomogeneities. Of course, this also applies to the manufacture of the compound.
  • Stabilizers, waxes, lubricants, release agents and other auxiliaries can be added as auxiliaries.
  • a preferred stabilizer comprises Ca-Zn and can be added in an amount between 1 and 3%, preferably 2% by weight of the mixture to be extruded.
  • PE waxes can be used as waxes.
  • Release agents used are CPE release agents, which are used in an amount between 0.5 and 1.5% by weight, preferably 1% by weight, in the mixture to be extruded.
  • CPE chlorinated polyethylene, a copolymer of ethylene and vinyl chloride. Unlike in PVC, the chlorine content in the polymer can vary depending on the ratio of the two monomers. CPE will e.g. used as an impact modifier.
  • the mixture is extruded in an extruder with discharge of a plate-shaped strand.
  • the mixture of PVC, CaCO 3 or limestone and other additives to be extruded is provided either beforehand by mixing the powdery ingredients, melting the PVC and cooling it down, or as a finished compound.
  • the mixture to be extruded then runs through a multi-stage extruder with zones at different temperatures, with partial cooling using water.
  • the mixture to be extruded is elasticized in the extruder under the influence of temperature and shearing force to form a "kneadable" mass.
  • a plate-shaped strand (e.g. with a maximum width of 1,400 mm) is discharged from the extruder via a slot die onto a roller conveyor.
  • the endless strand as such can be fed into the further processing plant for surface finishing in one variant.
  • the endless strand can be cut to length.
  • the endless strand is cut into separate half-formats and the half-formats are fed to further processing as a plastic carrier board. (. It is also possible to feed the half-formats into the processing plant as a quasi-panel train, i.e. edge to edge.
  • the surface of the plastic carrier plate is finished as follows:
  • the surface of the plastic carrier plate can be pretreated before printing to improve the adhesion of the subsequent layers. This can be cleaning with brushes, bevelling, which also removes unevenness from the surface, and/or plasma or corona treatment.
  • At least one primer is applied to the plastic carrier plate before it is printed on.
  • This primer comprises a hot melt (or hot coating) in the form of a polyurethane hot melt
  • the amount of liquid primer applied is presently between 1 and 30 g/m 2 , preferably between 5 and 20 g/m 2 , particularly preferably between 10 and 15 g/m 2 .
  • Polyurethane-based compounds are preferably used as primers.
  • a hotmelt e.g. in the form of a polyurethane hotmelt
  • a polyurethane hotmelt e.g. in the form of a polyurethane hotmelt
  • Both primer and hotmelt can contain inorganic color pigments and thus serve as a white primer layer for the decorative layer that is then to be printed on.
  • White pigments such as titanium dioxide TiO 2 can be used as color pigments.
  • Other color pigments can be calcium carbonate, barium sulfate or barium carbonate.
  • the primer consists of at least one, preferably at least two or more layers or applications applied one after the other, with the application quantity being the same or different between the layers or applications, i.e. the application quantity of each individual layer can vary.
  • the primer can be applied to the surface of the plastic backing sheet using a roller.
  • a white ground is applied to the primer by means of digital printing on the plastic carrier plate.
  • the digital printing inks used for the digital printing of the white background are preferably based on UV inks that are enriched with white color pigments.
  • An order using digital printing is advantageous because the printing system is significantly shorter than a roller device and thus saves space, energy and costs.
  • the at least one decor is applied to the (surface-treated and pre-coated) carrier board by means of digital printing processes upset.
  • digital printing the printed image is transferred directly from a computer to a printing machine, such as a laser printer or inkjet printer. This eliminates the use of a static printing form.
  • the decor is printed according to the inkjet principle in a single pass, in which the entire width of the upper side to be printed is spanned, with the plates being moved under the printer.
  • the carrier plate to be printed is stopped under the printer and the printer runs over the surface at least once during printing.
  • the printing colors are grouped together in separate rows of print heads, with one or two rows of print heads being able to be provided for each color.
  • the colors of the digital printing inks are, for example, black, blue, red, reddish yellow, greenish yellow, optionally CMYK can also be used.
  • the digital printing inks are optionally based on the same pigments used for analogue and/or digital printing with water-based inks.
  • the digital printing inks are preferably based on UV inks. However, it is also possible to use water-based digital printing inks or so-called hybrid inks. After printing, the decorative print is dried and/or irradiated.
  • the printing inks are applied in an amount between 1 and 30 g/m 2 , preferably between 3 and 20 g/m 2 , particularly preferably between 3 and 10 g/m 2 .
  • a first covering layer is applied to the decorative layer.
  • This first covering layer is applied to the decorative layer as a liquid application and consists of a hot-coating or hot-melt layer.
  • the use of a first covering layer is advantageous since improved adhesion of the subsequently scattered particles and the layers applied later is achieved.
  • a polyurethane hot melt (or polyurethane hot melt adhesive) is used as the hot coating or hot melt (hot melt adhesive).
  • the PUR hotmelt is applied at an application temperature of approx. 150°C.
  • the use of polyurethane as a hotmelt has the further advantage that post-crosslinking takes place with the surface of the plastic carrier plate, resulting in particularly good adhesion to the surface.
  • the amount of hot coating applied as the first covering layer is between 20 and 50 g/m 2 , preferably 30 and 40 g/m 2 .
  • abrasion-resistant particles are scattered onto the at least one first cover layer applied to the decorative layer.
  • the advantage of sprinkling on the abrasion-resistant particles is that the quantity and distribution can be adjusted quickly and in a targeted manner, and a quick changeover to different product requirements is possible.
  • particles of corundum (aluminum oxides), boron carbides, silicon dioxides, silicon carbides are used as abrasion-resistant particles.
  • Corundum particles are particularly preferred. This is preferably a high-grade corundum (white) with a high level of transparency, so that the optical effect of the underlying decoration is adversely affected as little as possible. Corundum has an uneven three-dimensional shape.
  • the amount of abrasion-resistant particles scattered on is 10 to 50 g/m 2 , preferably 10 to 30 g/m 2 , particularly preferably 15 to 25 g/m 2 .
  • the amount of abrasion-resistant particles scattered depends on the abrasion class to be achieved and the grain size.
  • the amount of abrasion-resistant particles in the case of abrasion class AC3 is in the range between 10 and 15 g/m 2 , in abrasion class AC4 between 15 and 20 g/m 2 and in abrasion class AC5 between 20 and 25 g/m 2 during use of grit F220.
  • the finished panels preferably have abrasion class AC4.
  • the test is carried out according to DIN EN 16511 - May 2014 Method A or B "Panels for floating installation - Semi-rigid, multi-layer, modular floor coverings (MMF) with abrasion-resistant top layer".
  • Abrasion-resistant particles with grain sizes in classes F180 to F240 are used.
  • the grain size of class F180 covers a range from 53 - 90 ⁇ m, F220 from 45-75 ⁇ m, F230 34-82 ⁇ m, F240 28-70 ⁇ m (FEPA standard).
  • class F220 corundum particles are used
  • the abrasion-resistant particles must not be too fine-grained (risk of dust formation), but also not too coarse-grained. The size of the abrasion-resistant particles is therefore a compromise.
  • silanized corundum particles can be used.
  • Typical silanizing agents are aminosilanes. The silanization of the corundum particles enables improved adhesion ("docking") of the corundum particles on the layers provided.
  • the at least one second cover layer also consists of a hot coating or hot melt, e.g. a PU hot melt.
  • This second covering layer serves a) to cover the decor, b) as a structural support and c) with the sprinkled corundum, ensures wear resistance against abrasion.
  • the quantity of the hot coating applied to the layer of scattered abrasion-resistant particles varies depending in particular on the quantity of the first covering layer applied to the printed decoration.
  • the amount of hot coating applied as the second covering layer is in a range between 20-50 g/m 2 , preferably 30-40 g/m 2 .
  • the second covering layer is structured in a next step.
  • the structuring is usually realized by a structured roller.
  • a structuring agent e.g. structuring foil, structuring paper
  • the structure in the register may run parallel to the decor, the so-called EIR structure or decor-synchronous structure.
  • the position and speed between the carrier plate to be structured and the structuring agent (roller and/or structuring paper) are synchronized.
  • the at least one lacquer layer is then applied to the at least one second, now structured cover layer, the at least one lacquer layer consisting of a top coat with nanoparticles, e.g. nanoparticles made of silica.
  • the at least one lacquer layer serves to improve the scratch resistance and, if necessary, to adjust the degree of gloss.
  • the lacquer layer consists of a top coat with nanoparticles, for example made of silicic acid.
  • the paint preferably a PU paint, can be applied in an amount between 40 and 60 g/m 2 , preferably 50 g/m 2 , using additional rollers.
  • radiation-curable acrylate-containing lacquers are used for the top coat.
  • the radiation-curable lacquers used typically contain (meth)acrylates, such as polyester (meth)acrylates, polyether (meth)acrylates, epoxy (meth)acrylates or urethane (meth)acrylates.
  • the acrylate used or the acrylate-containing paint substituted or unsubstituted monomers, oligomers and / or Polymers, in particular in the form of acrylic acid, acrylic ether and/or acrylic acid ester monomers, oligomers or polymers.
  • the presence of a double bond or unsaturated group in the acrylate molecule, as defined, is important for the present process.
  • the polyacrylates can also be functionalized. Suitable functional groups include hydroxy, amino, epoxy and/or carboxyl groups.
  • the acrylates mentioned enable crosslinking or curing in the presence of UV or electron beams (ESH).
  • the above-mentioned structuring e.g. by means of a structuring agent or a structured roller
  • the structuring is only carried out after the application of the final top coat.
  • the layer structure is already cured together with the structuring agent, so that the curing takes place largely in the absence of oxygen (i.e. inert), which means that high gloss levels can be achieved.
  • the layer structure is finally dried and cured.
  • Radiation curing is thus preferably effected by the action of high-energy radiation such as UV radiation or by irradiation with high-energy electrons.
  • Lasers, high-pressure mercury vapor lamps, flashlights, halogen lamps or excimer radiators are preferably used as radiation sources.
  • the radiation dose usually sufficient for curing or crosslinking is in the range of 80-3000 mJ/cm 2 in the case of UV curing.
  • the irradiation can also be carried out in the absence of oxygen, ie in an inert gas atmosphere. In the presence of oxygen, ozone is formed, causing the surface to become dull.
  • Suitable inert gases include nitrogen, noble gases or carbon dioxide.
  • the present process is preferably carried out under a nitrogen atmosphere.
  • the surface-finished panel format can be profiled lengthways and crossways on milling machines, but separately so that the milling waste can be recycled.
  • a lockable tongue and groove connection is introduced on at least two opposite edges of the panel. This enables the panels to be laid in a floating manner quickly and easily.
  • Such tongue and groove connections are, inter alia, from EP 1 084 317 B1 famous.
  • the abrasion-resistant and waterproof panels have a bulk density of between 1500 and 3000 kg/m 3 , preferably 2000 and 2500 kg/m 3 .
  • the overall layer thickness of the panels is less than 6 mm, between 3 and 5 mm, preferably 3 and 4.5 mm.
  • a white background is provided between the primer and the printed decorative layer.
  • the present panel can also have a structuring in the paint layer that finishes off the overall structure (reference is made to the above explanations in this regard).
  • the manufacturing process for the plastic carrier plate can be upstream.
  • This section includes at least one mixing device for mixing the starting materials for the plastic carrier board in the processing direction.
  • the thermoplastic material, in particular PVC, limestone and other additives are mixed together in the mixing device.
  • the partial section of the production line comprises at least one intermediate bunker arranged behind the mixing device in the processing direction for storing the mixture of plastic, limestone and other additives.
  • An extruder follows the intermediate bunker in the processing direction. It is also possible to dispense with the mixing device and intermediate bunker. In this case, a finished compound is prepared from the starting materials (e.g. in the form of pellets) and fed into the extruder.
  • the mixture (powder or compound) is elasticized in the extruder and pressed through a profile to form an endless strand (SPC strand), which is cut to length (i.e. cut to the desired format) and the individual formats are stacked as carrier plates before further processing.
  • SPC strand endless strand
  • the carrier plates are separated and first subjected to a pretreatment, such as grinding, which also removes unevenness from the surface, and/or a plasma or corona treatment.
  • a pretreatment such as grinding, which also removes unevenness from the surface, and/or a plasma or corona treatment.
  • the devices required for this are known.
  • a primer e.g. primer or hotmelt, possibly enriched with white pigments
  • the application device used for this is preferably designed in the form of a roller unit.
  • a white base is then applied to the primer using a digital printer.
  • a digital printer is also used to print the decorative layer.
  • the at least one device provided downstream of the printer in the processing direction for applying at least one first cover layer to the decorative layer is preferably designed in the form of a roller application device or a spray unit.
  • the scattering device for the abrasion-resistant particles provided in the present production line is suitable for scattering powder, granules, fibers and includes an oscillating brush system.
  • the spreading device essentially consists of a storage hopper, a rotating, structured roller and a scraper. The amount of abrasion-resistant material applied is determined by the rotational speed of the roller.
  • the spreading device preferably comprises a spiked roller.
  • the at least one scattering device is surrounded or arranged in at least one cabin, which is provided with at least one means for removing dust occurring in the cabin.
  • the means for removing the dust can be designed in the form of a suction device or as a device for blowing in air. Air injection can be achieved via nozzles installed at the plate inlet and outlet, blowing air into the booth. In addition, they can prevent an inhomogeneous scatter curtain of abrasion-resistant material from arising due to air movements.
  • the removal of the dust from abrasion-resistant material from the vicinity of the spreading device is advantageous because, in addition to the obvious health hazards for the workers working on the production line, the fine dust from abrasion-resistant particles also settles on other parts of the production line and leads to increased wear on the same.
  • the arrangement of the scattering device in a cabin is therefore not only used Reduction of health dust pollution of the environment of the production line, but also prevents premature wear.
  • the spreading device is followed by the device for applying the at least one second covering layer, preferably in the form of a hot coating, which is also present as a roller unit.
  • the final layer of lacquer is also applied using a roller device.
  • a structure roller can be provided between the device for applying the elastic layer (hotcoating) and the roller device for applying the final lacquer layer and/or following the latter.
  • the application devices are followed by devices for curing the layer structure, such as dryers and/or radiators.
  • the production line shown schematically comprises a first section 1 for the production of the plastic carrier plate and a second section 2 for the surface treatment of the plastic carrier plate.
  • Section 1 initially comprises a reservoir 10 for PVC powder and a reservoir 11 for limestone, which are mixed with one another in the mixing device 13 with the addition of further auxiliary substances 12 .
  • This powdered mixture of PVC, limestone (or chalk) and other additives can be temporarily stored in an intermediate bunker 14.
  • the intermediate bunker 14 is arranged behind the mixing device in the processing direction.
  • the extruder 15 follows the intermediate bunker 14 in the processing direction.
  • a compound made from the individual components in pellet form can also be used directly as the starting component for the extruder 15 .
  • storage containers 10, 11, 12, mixing device 13 and intermediate bunker 14 can be dispensed with.
  • the mixture (powder or compound) is fed into the extruder device 15 and pressed through a profile to form an endless strand (SPC strand).
  • the extruder device 15 is designed as a multi-stage extruder with zones at different temperatures, with partial cooling using water.
  • a plate-shaped strand (e.g. with a maximum width of 1,400 mm) is discharged from the extruder via a slot nozzle onto a roller conveyor 16, cut to size and stacked.
  • Section 2 for the surface treatment of the plastic carrier plate begins with the separation and pretreatment of the carrier plates, such as sanding and/or plasma or corona treatment (not shown).
  • At least one primer preferably a white-pigmented PUR hotmelt, is applied to the surface of the plastic carrier plate using a roller unit 20 .
  • a digital printer 21 for applying a white ground followed by one or more digital printers 22 for printing the decorative layer.
  • the decor is printed according to the inkjet principle in a single pass, in which the entire width of the upper side to be printed is spanned, with the plates being moved under the printer
  • the at least one device provided downstream of the printer 22 in the processing direction for applying a hot coating (PUR hotmelt) as the first cover layer to the decorative layer is designed as a roller application device 23 .
  • a first scattering device 24 is provided for evenly scattering the abrasion-resistant material, such as corundum, on the upper side of the plastic carrier plate.
  • Corundum F220 is used as the abrasion-resistant material, which measures around 45-75 ⁇ m in diameter according to the FEPA standard.
  • the spreading device 24 essentially consists of a storage funnel, a rotating, structured spiked roller and a scraper.
  • the application quantity of the material is determined by the rotational speed of the spreader roller.
  • the corundum falls from the spiked roller at a distance of 5 cm onto the plate covered with the decorative foil.
  • the scattering device 24 is followed by the device 25 for applying a hot coating as the second covering layer.
  • a PUR hotmelt is used as the hotcoating.
  • the final lacquer layer is also applied using a roller device 27 .
  • a structure roller 26 is provided between the device 25 for applying the second covering layer and the roller device 27 for applying the final layer of lacquer.
  • the application devices are followed by devices for curing the layer structure, such as dryers and/or radiators (not shown). Suitable cooling devices and cutting devices are provided (not shown) for further assembly.

Landscapes

  • Engineering & Computer Science (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Wood Science & Technology (AREA)
  • Mechanical Engineering (AREA)
  • Laminated Bodies (AREA)
  • Application Of Or Painting With Fluid Materials (AREA)
  • Panels For Use In Building Construction (AREA)

Claims (10)

  1. Procédé de fabrication d'un panneau multicouche résistant à l'abrasion et à l'eau, en particulier d'un panneau de plancher résistant à l'abrasion et à l'eau, comprenant les étapes :
    - de fourniture d'au moins une plaque de support en PVC ;
    - d'application d'au moins un apprêt comprenant au moins une colle thermofusible de polyuréthane sur la surface de la plaque de support en PVC ;
    - d'application d'au moins une base blanche sur l'apprêt ;
    - d'impression de la plaque de support en PVC lors de l'impression directe en réalisant une couche décorative ;
    - d'application d'au moins une première couche de recouvrement comprenant une colle thermofusible de polyuréthane sur la couche décorative imprimée ; dans lequel la quantité de colle thermofusible de polyuréthane en tant que première couche de recouvrement est comprise entre 20 et 50 g/m2, de manière préférée 30 et 40 g/m2 ;
    - de répartition homogène de particules résistantes à l'abrasion sur l'au moins une couche couvrante appliquée sur la couche décorative ;
    - d'application d'au moins une deuxième couche de recouvrement comprenant une colle thermofusible de polyuréthane sur la strate de particules résistantes à l'abrasion réparties ; dans lequel la quantité de la colle thermofusible de polyuréthane en tant que deuxième couche de recouvrement varie en fonction de la quantité de la première couche de recouvrement appliquée sur le motif décoratif imprimé et est comprise entre 20 et 50 g/m2, de manière préférée 30 et 40 g/m2 ;
    - de mise en place d'une structure dans l'au moins une deuxième couche de recouvrement ;
    - d'application d'au moins une couche de vernis ; et
    - de durcissement de la structure en couches,
    dans lequel la colle thermofusible de polyuréthane est appliquée à une température d'application d'environ 150 °C.
  2. Procédé selon la revendication 1, caractérisé en ce que la surface de la plaque de support en PVC est prétraitée avant l'impression pour l'amélioration de l'adhérence des couches qui suivent, de manière préférée au moyen d'un ponçage.
  3. Procédé selon l'une quelconque des revendications précédentes, caractérisé en ce que l'apprêt à appliquer avant l'impression sur la surface de la plaque de support en PVC comprend au moins une couche primaire.
  4. Procédé selon l'une quelconque des revendications précédentes, caractérisé en ce que la base blanche est appliquée sur l'apprêt au moyen d'une impression numérique.
  5. Procédé selon l'une quelconque des revendications précédentes, caractérisé en ce qu'au moins une couche décorative est appliquée lors de l'impression numérique.
  6. Procédé selon l'une quelconque des revendications précédentes, caractérisé en ce que des particules composées de corindon (oxydes d'aluminium), de carbures de bore, de dioxydes de silicium, de carbures de silicium sont utilisées en tant que particules résistantes à l'abrasion.
  7. Procédé selon l'une quelconque des revendications précédentes, caractérisé en ce que l'au moins une couche de vernis est constituée d'un vernis couvrant UV.
  8. Procédé selon l'une quelconque des revendications précédentes, caractérisé en ce qu'une structure est mise en place dans l'au moins un vernis couvrant.
  9. Procédé selon l'une quelconque des revendications précédentes, caractérisé en ce qu'une liaison à rainure et à languette verrouillable est mise en place sur au moins deux bords se faisant face du panneau.
  10. Ligne de production pour la mise en oeuvre d'un procédé selon l'une quelconque des revendications 1-9, comprenant
    - au moins un dispositif d'application pour appliquer au moins un apprêt comprend au moins une colle thermofusible de polyuréthane sur l'au moins une plaque de support en PVC ;
    - au moins une imprimante numérique pour appliquer au moins une base blanche sur l'apprêt ;
    - au moins une imprimante pour appliquer au moins une couche décorative ;
    - au moins un dispositif prévu après l'imprimante dans le sens de traitement pour appliquer au moins une première couche de recouvrement comprenant une colle thermofusible de polyuréthane sur la couche décorative ;
    - au moins un dispositif pour répartir une quantité prédéfinie de particules résistantes à l'abrasion ; et
    - au moins un dispositif disposé après le dispositif de répartition dans le sens de traitement pour appliquer au moins une deuxième couche de recouvrement comprenant une colle thermofusible de polyuréthane,
    - au moins un cylindre à structure pour mettre en place une structure dans l'au moins une deuxième couche de recouvrement ; et
    - au moins un dispositif pour appliquer une couche de vernis.
EP19153171.4A 2019-01-23 2019-01-23 Procédé de fabrication d'un panneau multicouche résistant à l'abrasion et à l'eau Active EP3686029B1 (fr)

Priority Applications (7)

Application Number Priority Date Filing Date Title
ES19153171T ES2916708T3 (es) 2019-01-23 2019-01-23 Procedimiento para la fabricación de un panel multicapa resistente a la abrasión y al agua
PL19153171.4T PL3686029T3 (pl) 2019-01-23 2019-01-23 Sposób produkcji wielowarstwowego panelu odpornego na ścieranie i wodę
EP19153171.4A EP3686029B1 (fr) 2019-01-23 2019-01-23 Procédé de fabrication d'un panneau multicouche résistant à l'abrasion et à l'eau
PT191531714T PT3686029T (pt) 2019-01-23 2019-01-23 Processo para a produção de um painel de multicamadas resistente à abrasão e à prova de água
US17/425,103 US12311404B2 (en) 2019-01-23 2020-01-09 Method for producing an abrasion- and water-resistant multilayer panel and a panel which is produced using said method
CN202080010254.5A CN113348094A (zh) 2019-01-23 2020-01-09 用于制造耐磨且防水的多层镶板的方法和借助该方法制造的镶板
PCT/EP2020/050436 WO2020151956A1 (fr) 2019-01-23 2020-01-09 Procédé de fabrication d'un panneau multicouche résistant à l'abrasion et à l'eau et panneau fabriqué selon ledit procédé

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
EP19153171.4A EP3686029B1 (fr) 2019-01-23 2019-01-23 Procédé de fabrication d'un panneau multicouche résistant à l'abrasion et à l'eau

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EP3686029A1 EP3686029A1 (fr) 2020-07-29
EP3686029B1 true EP3686029B1 (fr) 2022-04-20

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EP (1) EP3686029B1 (fr)
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DE102022107719B4 (de) * 2022-03-31 2024-12-24 Renolit Se UV Schutzfolie für den Außenbereich

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WO2020151956A1 (fr) 2020-07-30
ES2916708T3 (es) 2022-07-05
PL3686029T3 (pl) 2022-09-12
EP3686029A1 (fr) 2020-07-29
PT3686029T (pt) 2022-06-15
US20220105539A1 (en) 2022-04-07
CN113348094A (zh) 2021-09-03
US12311404B2 (en) 2025-05-27

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