Classifications

• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
  • E04F13/00—Coverings or linings, e.g. for walls or ceilings
  • E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
  • E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
  • E04F13/0875—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements having a basic insulating layer and at least one covering layer
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B44—DECORATIVE ARTS
  • B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
  • B44C1/00—Processes, not specifically provided for elsewhere, for producing decorative surface effects
  • B44C1/24—Pressing or stamping ornamental designs on surfaces
• • 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
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
  • E04B9/00—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation
  • E04B9/04—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation comprising slabs, panels, sheets or the like
  • E04B9/045—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation comprising slabs, panels, sheets or the like being laminated
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
  • E04F13/00—Coverings or linings, e.g. for walls or ceilings
  • E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
  • E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
  • E04F13/0871—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements having an ornamental or specially shaped visible surface
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
  • E04F13/00—Coverings or linings, e.g. for walls or ceilings
  • E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
  • E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
  • E04F13/0889—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements characterised by the joints between neighbouring elements, e.g. with joint fillings or with tongue and groove connections
  • E04F13/0894—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements characterised by the joints between neighbouring elements, e.g. with joint fillings or with tongue and groove connections with tongue and groove connections
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
  • E04F13/00—Coverings or linings, e.g. for walls or ceilings
  • E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
  • E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
  • E04F13/16—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements of fibres or chips, e.g. bonded with synthetic resins, or with an outer layer of fibres or chips
• • 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
  • E04F15/02005—Construction of joints, e.g. dividing strips
• • 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
  • E04F15/02038—Flooring or floor layers composed of a number of similar elements characterised by tongue and groove connections between neighbouring flooring elements
• • 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
  • E04F15/102—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 of fibrous or chipped materials, e.g. bonded with synthetic resins
• • 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
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
  • E04F15/00—Flooring
  • E04F15/18—Separately-laid insulating layers; Other additional insulating measures; Floating floors
  • E04F15/181—Insulating layers integrally formed with the flooring or the flooring elements
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
  • E04F15/00—Flooring
  • E04F15/18—Separately-laid insulating layers; Other additional insulating measures; Floating floors
  • E04F15/20—Separately-laid insulating layers; Other additional insulating measures; Floating floors for sound insulation
  • E04F15/206—Layered panels for sound insulation
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
  • E04F2201/00—Joining sheets or plates or panels
  • E04F2201/02—Non-undercut connections, e.g. tongue and groove connections
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
  • E04F2201/00—Joining sheets or plates or panels
  • E04F2201/03—Undercut connections, e.g. using undercut tongues or grooves
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
  • E04F2290/00—Specially adapted covering, lining or flooring elements not otherwise provided for
  • E04F2290/04—Specially adapted covering, lining or flooring elements not otherwise provided for for insulation or surface protection, e.g. against noise, impact or fire
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
  • E04F2290/00—Specially adapted covering, lining or flooring elements not otherwise provided for
  • E04F2290/04—Specially adapted covering, lining or flooring elements not otherwise provided for for insulation or surface protection, e.g. against noise, impact or fire
  • E04F2290/041—Specially adapted covering, lining or flooring elements not otherwise provided for for insulation or surface protection, e.g. against noise, impact or fire against noise
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
  • E04F2290/00—Specially adapted covering, lining or flooring elements not otherwise provided for
  • E04F2290/04—Specially adapted covering, lining or flooring elements not otherwise provided for for insulation or surface protection, e.g. against noise, impact or fire
  • E04F2290/045—Specially adapted covering, lining or flooring elements not otherwise provided for for insulation or surface protection, e.g. against noise, impact or fire against fire

Definitions

• the present invention relates to a covering element for ceilings, walls or floors for indoor use as well as for outdoor use.
• Wall or floor covering elements particularly for interior use, are known that consist of a wood-containing core board or plastic, especially HDF, onto which a top layer is applied.
• the side edges of the floor covering element have either projections or recesses on the opposite sides, which interlock when the covering elements are arranged side by side, thus facilitating easier installation of the covering elements to form a continuous covering.
• Such a connection is also often called a click connection because it allows even inexperienced persons to install a covering made of several elements without gaps.
• the object of the present invention is to further develop a coating element in such a way that it is individually configurable and insensitive to moisture and temperature changes.
• the carrier plate is designed as a mineral carrier plate, i.e., it contains at least one mineral which is pressed together to form a plate by means of, for example, a polymeric adhesive.
• the pressing can be done cold or possibly under pressure. Thermal action is required.
• Particles, especially polymer fibers or natural fibers, can serve as adhesive materials and stabilizers, leading to good bonding (solidification) of the mineral particles, particularly under the influence of temperature and pressure, especially if they are fibrous.
• the backing board is designed as a preferably flat, mineral backing board based on cement or with a cement content of between 25 and 85 percent by volume, preferably between 35 and 50 percent by volume.
• the backing board is preferably designed as a cement fiberboard.
• Such a backing board further comprises a fiber reinforcement, for example, between 1 and 40 percent by volume of reinforcing fibers, preferably between 2 and 20 percent by volume.
• the reinforcing fibers are preferably glass fibers and/or plastic fibers, as well as polyvinyl or polyethylene-based fibers.
• the cement fiberboard may also contain fibers required for the production of the board that provide no, or almost no, reinforcement or strengthening of the board.
• the proportion of these so-called process fibers is preferably between 1 and 40 percent by volume, more preferably between 2 and 20 percent by volume.
• the plates of this preferred embodiment are manufactured using the so-called Hatschek process, for example, using a process such as the one described in US 4,428,775 described procedure.
• the presence of fibers, reinforcing fibers, and/or process fibers in the mineral substrates used according to several preferred embodiments of the invention offers significant advantages.
• the reinforcing fibers provide the recesses and projections with suitable interlocking strength.
• the process fibers ensure adequate adhesion with any type of decorative layer applied at least partially in liquid form, thus reducing the risk of delamination between the decorative layer and the substrate.
• This coating element according to the invention is that it is both insensitive to thermal stresses and insensitive to moisture.
• the substrate consists of mineral elements pressed together with plastic or natural fibers, with the plastic fibers preferably comprising a volume fraction of 1-40%.
• plastic or natural fibers preferably comprising a volume fraction of 1-40%.
• Such a substrate has proven to be highly water-resistant, thermally resistant, and, above all, mechanically stable. Furthermore, such a substrate can be readily coated with a decorative layer on its surface.
• the carrier panel has an insulating layer on its back side, in particular an elastomer layer, preferably a foamed polymer, especially an elastomer, or a natural product based on cork or wood, in order to provide impact sound insulation and/or thermal insulation to the substrate or wall.
• an insulating layer on its back side, in particular an elastomer layer, preferably a foamed polymer, especially an elastomer, or a natural product based on cork or wood, in order to provide impact sound insulation and/or thermal insulation to the substrate or wall.
• an insulating layer preferably a foamed polymer, especially an elastomer, or a natural product based on cork or wood, in order to provide impact sound insulation and/or thermal insulation to the substrate or wall.
• Such covering elements could also be used for thermal insulation on exterior facades.
• this insulating layer also serves as a counter-tension to prevent the panel from deforming when coated on only one side.
• the coating element of the invention includes a barrier layer on the back of the carrier plate to prevent the penetration of moisture and/or vapors from below.
• a barrier layer can, for example, consist of a liquid-applied layer of material or of a prefabricated layer bonded to the back.
• the aforementioned insulating layer can simultaneously function as a barrier layer. Blocking moisture and/or vapors is advantageous in order to reduce or completely prevent any tendency of the covering element to warp. Such warping or tendency to warp leads to stresses in the covering, and particularly in the area of interlocking recesses and projections. These stresses can lead to defects.
• the decorative layer consists of a base layer containing color pigments applied to the substrate, on which at least a color pigment-containing digital print layer is arranged.
• a base layer containing color pigments applied to the substrate, on which at least a color pigment-containing digital print layer is arranged.
• at least one polymer-containing transparent top layer is arranged, which preferably has a structured surface.
• the base layer can also be transparent, i.e., free of color pigments, or comprise one or more transparent layers.
• a decorative layer based on digital printing offers a high degree of customization due to the digital printing process. For example, different materials such as wood, leather, or stone, or fantasy designs can be imitated.
• the effect created by the digital printing is enhanced by the structured surface, so that any desired structures, such as wood textures, stone textures, and the like, can be simulated very effectively with the coating element according to the invention.
• the top layer contains polyurethane or acrylic, which is very well suited as an abrasion-resistant top layer and also possesses the necessary transparency to allow the base layer and/or the digital print layer to show through.
• the top layer contains particles such as corundum (aluminum oxide) or silicon carbide. These particles provide increased abrasion resistance.
• the top layer contains an electron beam-curing polymer or a UV-curing polymer, for example acrylic-based, wherein the top layer is cured according to the
• the surface texture of the covering element can be replicated with a structure simulated by the digital print layer, for example, using a textured roller. This allows the surface structure to be realistically reproduced, such as a wood or stone surface.
• the top layer consists of a composite layer of a polymeric matrix material with binding properties and a filler material.
• This composite layer is preferably applied to the substrate in liquid or solid form, such as sheets or rolls.
• the liquid application allows the composite layer to bond very well with the mineral-containing substrate, and by selecting the appropriate filler material, such as leather particles, wood particles, or cork particles, a desired texture can be effectively replicated through the composite layer.
• This embodiment therefore represents a cost-effective alternative to digital printing.
• the surface of the mixture layer is structured, which can be achieved, for example, by treatment with an embossing roller, especially while the mixture layer has not yet hardened after application, particularly under elevated temperatures between 40 and 100 degrees Celsius.
• the decorative layer comprises a film, either printed or unprinted, or consists of such a film.
• the film can be paper-based or plastic-based, as well as PVC (polyvinyl chloride), PP (polypropylene), PET (polyethylene terephthalate), polyolefin, and the like.
• the film is preferably bonded to the substrate.
• a liquid adhesive is preferably applied to the substrate.
• this adhesive application achieves at least partial penetration into the substrate.
• the recesses and projections forming the tongue-and-groove joint in the substrate can be incorporated into the substrate before or after the decorative layer is applied. This is particularly possible because the recesses and projections are located solely in the substrate and not in the decorative layer.
• the invention also relates to a method for manufacturing a wall or floor covering element, in which a mineral carrier board, i.e., comprising at least one mineral material, is coated with a decorative layer, wherein, before or after the application of the decorative layer, recesses and projections are created on opposite side edges of the carrier board by milling, forming a tongue and groove connection that interlocks positively when covering elements are placed side by side.
• the tongue and/or groove is realized by means of a milling process with at least two successive milling passes using milling cutters that are positioned at different angles relative to the covering element in question. For example, during each of the aforementioned milling passes, each The main focus is on realizing the final shape of a flank, either the tongue or the groove.
• the substrate is coated with a base layer or primer, which preferably contains a polymer material containing color pigments.
• a base layer or primer which preferably contains a polymer material containing color pigments.
• at least one color pigment-containing digital print layer is applied to the base layer using a digital printing process.
• at least one polymer-containing transparent top layer e.g., polyurethane or acrylic, is applied to this top layer.
• the application process takes place at a temperature elevated above room temperature, particularly in a temperature range of 40–100°C, and especially in a temperature range of 60–100°C.
• color pigment encompasses not only colored pigments but also white and black pigments.
• a surface texture is applied to the top layer, preferably at elevated temperature, particularly at 40-100°C, preferably by embossing with at least one structured embossing roller.
• the coating element very effectively creates a desired surface impression, e.g., the impression of a wood or stone surface.
• a decorative layer is applied to the substrate.
• This layer consists of a mixture of a curable polymer and a filler material.
• the filler material can be aggregate, sand, rock flour, wood fibers, wood flour, or leather fibers or leather flour.
• the mixture is cured, for example, chemically, thermally, or optically (UV). Linoleum and/or plastic fibers and/or stone particles can also be incorporated into the mixture.
• the mixed layer is structured on its surface at elevated temperature, particularly at 40-100°C, especially by means of an embossing roller, so that the optical impression created by the mixed layer can be emphasized by the surface structure.
• the composite layer is cured to an elastic modulus of 0.05–0.5 GPa.
• the cured composite layer thus exhibits elasticity in the rubber range, allowing for the effective imitation of, for example, leather or rubber surfaces.
• the curing of the composite layer can be achieved thermally using UV light or chemically.
• the top layer is preferably applied as a hot coating using a hot embossing roller.
• the transparent top layer can be a single layer or can consist of several superimposed layers.
• this top layer is formed by at least one layer of a UV-curing varnish.
• the transparent topcoat contains abrasion-resistant particles as well as corundum (aluminum oxide). These hard particles can be incorporated into the topcoat by scattering or can be mixed into the actual topcoat material and applied together with it. It is possible for the topcoat to be applied in several layers, with only some of these layers containing the aforementioned particles.
• the coating element of the invention preferably features at least one surface penetration of the decorative layer material into the substrate. It is also evident that this refers to the material of the lower layer(s) of the decorative layer. Such penetration is advantageous for both multi-layered panels, as mentioned above, and single-layered panels. In both cases, improved adhesion of the decorative layer to the substrate is achieved. Furthermore, a potentially brittle decorative layer, for example in the case of digital printing, is strengthened by this anchoring in the substrate. For substrates that partially contain fibers, such as process fibers, made of cellulose or another, preferably absorbent, material, the adhesion is further improved. To further enhance penetration, the substrate preferably has a porosity of more than 10% by volume, and more preferably between 15% and 40% by volume.
• the invention also relates to a covering composed of several covering elements interlocking with each other by means of recesses and projections formed on the side edges.
• FIG. 1 shows a slab-shaped covering element 10, which can be combined with other covering elements 10 to form a floor covering, ceiling covering, and/or wall covering, also for outdoor use.
• the covering element 10 contains a mineral-based carrier board 12, which has either projections 14 or recesses 16 on its opposite side edges 17, 19. These projections form interlocking tongue-and-groove joints when the covering elements are placed side by side. Thus, when covering elements 10 are placed side by side, the projections 14 of one covering element 10 engage in the recess 16 of the adjacent covering element 10. On the back side, or rather,
• An insulating layer 18 for impact sound insulation and/or thermal insulation can optionally be arranged on the underside of the carrier plate 12. This layer is preferably applied directly to the carrier plate 12 or bonded to it.
• a base layer 20 containing color pigments is applied to give the substrate a desired base color.
• This base layer is preferably optional, as, in principle, the color of the substrate can serve as a base for a subsequent digital printing process, depending on the material of the substrate 12.
• a digital printing layer 22 is applied to the base layer 20 using a digital printing process. This digital printing layer 22 is not applied across the entire surface, but only in the areas to be printed.
• a structure 26 is applied to this top layer 24 using an embossing roller, particularly in a hot-coating process.
• This structure preferably reinforces the impression created by the digital printing layer 22.
• a surface slab is created that very well reflects an impression of a desired material, e.g. a layer of wood, a layer of leather, a layer of stone or a layer of cork.
• the top layer 24 can also be formed by several layers of a polymer, particularly one that is UV-curable.
• the application and profiling of the top layer 24 are preferably carried out using a hot roller in a hot-coating process.
• the hot-coating process itself is known.
• Fig. 2 shows an alternative embodiment of a covering element, wherein identical or functionally equivalent parts are used.
• Fig. 1 are marked with the same reference symbols.
• the floor covering element 30 made of Fig. 2 It also has a carrier plate 12, which contains minerals and has projections 14 and recesses 16 adjacent to each other. The facing side edges 17, 19 have [features].
• the projections and recesses of this tongue and groove system are shown only schematically. In practice, the projections 14 and recesses 16 are manufactured as shown in the EP 0843763 The invention described above is hereby made the subject of this application.
• a covering element according to the invention is generally rectangular, in particular square, and that the recesses and projections are formed on four sides, wherein the recesses 16 are preferably arranged on two adjacent sides and the projections 14 on the other two adjacent sides.
• the mineral carrier board 12 optionally has an insulating layer 18, as already mentioned. Fig. 1 This insulating layer is optional and only required if impact sound insulation and/or thermal insulation are desired. Furthermore, this insulating layer can also be used as a leveling counter-layer if needed.
• the carrier panel 12 On its upper surface, the carrier panel 12 carries a composite layer 32 consisting of a polymer and a filler. Suitable fillers include, for example, leather, cork, wood, stone, mineral powders, and sand, which can be provided either as particles or as fibers within the polymer matrix of the composite layer.
• the composite layer is preferably an elastomer layer that cures to a modulus of elasticity of 0.05–0.5 GPa, giving it a rubber-like elasticity.
• a cork, wood, or leather impression can be very effectively emphasized.
• Such a covering element is very well suited as a wall covering element.

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• Engineering & Computer Science (AREA)
• Architecture (AREA)
• Civil Engineering (AREA)
• Structural Engineering (AREA)
• Physics & Mathematics (AREA)
• Electromagnetism (AREA)
• Laminated Bodies (AREA)
• Finishing Walls (AREA)
• Floor Finish (AREA)

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• 2016
  • 2016-03-23 ES ES16161925T patent/ES2927610T3/es active Active
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  • 2016-03-23 EP EP16161925.9A patent/EP3222795B1/fr active Active
• 2017
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