DE102004056584B4 - Panels for floor, wall and ceiling coverings and a method for their manufacture - Google Patents

Abstract

panels for floor, Wall or ceiling coverings, which has a base plate having on its top with a Decor and a seal is provided, with the base plate on its underside with a backslash and the top of the base plate sanded and with a Primer is provided and on the primer a filler material is applied, characterized in that the filler material a base color coating is applied and that on the base color coating a color decor is printed, which with a seal and a Topcoat coating is provided, which consists of a 1st topcoat layer and a second topcoat layer exists.

Description

The The invention relates to a panel for floor, wall or ceiling coverings and a Process for producing such a panel.

When flooring as well as for wall or ceiling paneling come many times today coverings from panels of different decor and geometrical configuration for use. In particular, the present invention relates on a floor covering from panels.

Far For example, laminate flooring is widespread. A laminate floor panel consists of a base plate made of fiber material, usually a high or medium-density fiberboard, on top of which a resinated Decor paper is applied. The decor paper determines the look of the laminate. The so-called overlay or the seal forms a special treated wear layer of paint, which gives the floor panels a high surface durability gives. On the underside of the base plate is a so-called Gegenzug applied. This serves the dimensional stability and the Moisture barrier. Optionally, further on the underside of a Impact sound insulation can be provided.

The Production of laminate floor panels as well as the production of wall or ceiling panels in a continuous flow process, where a large-area plate made a high- or medium-compressed fiber material as a base plate the multi-layered layer construction with decor paper, sealant as well Return receives. Subsequently the panel is divided into panels and along with the edges Tongue or tongue profiled.

Basically proven the known panels. Nevertheless, an improvement in the appearance of a panel and a rationalization desirable in the production process. In particular, floor panels under the daily Strain is heavily strained, is also a repair capability desirable. It may also be possible come to electrostatic charges of laminate flooring, resulting in the Practice proves unfavorable.

By WO 2004/042 168 A1 discloses a panel for floor, wall or ceiling coverings, which has a base plate having on its top with a Decor and a seal is provided. The base plate is on their bottom with a backslash Mistake. The top of the base plate is sanded as well provided with a primer, applied to the a filler material is. On the putty material, a color decor is printed with a seal and a topcoat coating is provided.

The EP 1 240 026 B1 describes a method for producing a decoration on surface elements, for example floor coverings or wall panels. Here, a fiberboard is sanded smooth and provided with a primer. After hardening of the primer a decor is printed on it.

Of the Invention is based on the object, an optical and application technology improved panels for Floor-, Wall or ceiling coverings too create and demonstrate a process for their production.

The solution of the objective Part of the task consists in a panel according to the features of claim 1.

advantageous embodiments the panels of the invention are the subject of the dependent claims 2 to 7.

The Base plate of the panels is on its underside with a backslash Mistake. The backslash consists of an aqueous or water-dilutable Preparation with impregnating Effect and serves for moisture barrier as well as for dimensional stability in return. The top of the base plate is sanded. This is done appropriately with an abrasive that has a 180 to 240 grit. Subsequently For example, a primer, preferably a water primer, is applied. The water primer draws into the material of the base plate and serves as an adhesion primer. To drying of the primer is applied to the base plate a filler material, preferably a water-roll filler applied. Basically also a UV scraper used. The putty material is highly opaque, with the color of the putty on the Basic or basic color of the later decoration is tuned. On the layer of putty material is then a Base color coating applied. Also has the base color coating high-covering properties with a decoration that matches the decor Coloring. The base color is a so-called water rolling base used, the in at least two, expediently three layers is applied. After drying the base coating There is a decorative color printing, in which the panels with at least one Printing ink is printed. According to the invention, the decor of the panels is typographically, preferably by a multi-color printing (one to three colors) generated. On the decor color printing is then preferably a multilayer, transparent Seal including a topcoat coating applied, which consists of a 1st topcoat layer and a second topcoat layer consists.

The decor print can be a naturge faithful and highly elegant appearance of the panels can be achieved. In particular, the reproduction of natural materials in dark decors, such as wood imitations, compared to the previously known panels have a significantly improved appearance and captivate with their transparency and brilliance. Different gloss levels from matt to high gloss are possible. Even unusual surface designs and optics can be achieved depending on the choice of printing ink and printing technology. A panel according to the invention, in particular a floor panel, captivates by its feel, since the surface feels softer and warmer than a laminate surface.

at damage a panel this can be repaired. All you need is a light one Sanding and re-sealing and painting.

In In addition, practical experiments were no appreciable electrostatic Charging the panels detected. This can be caused by the lower working temperatures during the manufacture of the floor panels be and that no pressing of the individual layers is required.

Next the optical or practical advantages is also a clear cost advantage of panels according to the invention to be expected by the nature of their production.

The Seal preferably consists of one in at least two layers applied sealing base layer and a sanding layer. The sealant basecoat Ensures the abrasion resistance and durability of the panels. In the preparation are the abrasion resistance mineral Substances, in particular corundum, incorporated. Corundum is a colorless Mineral and has a Mohs hardness from 9.0 up. Corundum is therefore to increase the abrasion resistance, in particular of floor panels, especially suitable.

The Sealant base coat can be made by irradiation with ultraviolet Light to be dried.

to Creation of smooth surfaces may be on the sanding base as part of the multi-layered seal another layer of filler is applied. This comes preferably a UV putty material used, which under ultraviolet Light hardens.

Finally is also the top coat coating two or more layers executed. The Topcoat coating ensures gloss levels and brilliance. To achieve different optics can be in the first deck layer a pore or structure are introduced. Also the order of a Pore printing ink on the first topcoat layer is possible. The outer conclusion then forms the second topcoat layer.

A possible Variant for producing the appearance of a painted pore is the second topcoat layer by means of an engraved roller with a Apply printing machine on the gelled first topcoat layer. In this procedure, the first topcoat should be dull and the second topcoat glossy or vice versa, to get a clearly visible result. By means of the engraved roller, a pore can be both positive and be printed negatively. additionally it is possible, to print a synchronous pore. That means the pore fits appropriately is matched to the decor image, for example, a real wood impression still to reinforce. Subsequently the painted plate is cured by means of UV radiation in a UV channel. at This procedure is the application of a filler layer on the color decoration is not essential.

The solution of the procedural part The object consists in a method according to the measures of claim 8th.

advantageous Embodiments of the method according to the invention show the claims 9 to 16 on.

The inventive method is described below with reference to the manufacture of a floor panel. It should be noted that basically a similar structure from the top and bottom of the panels to printing is possible. This opens up the opportunity in case of a faulty pressure, turn over the corresponding plate and reprint.

When Output plate comes a large-scale high or medium density fiberboard for use with a thickness of 6-8 mm in a dimension of 2,620 mm × 1,250 mm. The plate is Already sanded on both sides in the production with a 160 to 240 grit and drives in the continuous production process with the underside upwards into the machine. The output plate can also be precoated be, e.g. with paper or veneer.

The aqueous backsheet is then applied first, in an application amount of preferably 10-20 g / m ² . The backsheet is dried in a jet drying duct with hot air. The temperature of the hot air is preferably 120 ° C.

Thereafter, the plate is turned. The upper page is again sanded with a 160 to 240 sandpaper in the direction of rotation. Then the primer is applied. This is a water primer. The order quantity is between 6 and 15 g / m ² . The primer is dried in a jet drying duct with preferably 120 ° C hot air.

Subsequently, a high-coverage putty material is applied to the primer. In this case, a so-called water-roller spatula is used, which is applied rolling on an order of between 6 and 20 g / m ² . Also, the water roller spatula is dried in a jet drying duct with hot air. As a putty material and a UV scraper can be used, which is then dried by UV radiation.

The filled plate now receives a fine grinding, preferably by an abrasive with fine grain size. Even the fine sanding takes place in the longitudinal direction. This is followed by the coating of the plate followed by a single or multiple application of a base color. Here, a first base color is first applied. The base color is highly opaque and is also known as water rolling ground. The order quantity is 6-10 g / m ² . The first base color is dried after application in two nozzle drying channels with hot air. This is followed by a second and a third application of base color, without intermediate drying in an order of about 6 g / m ² . The application of the second and third base color takes place wet in wet without intermediate drying. The two basic colors are then dried in two nozzle drying channels again with hot air.

To the drying of the base color coating is this with a decor print Mistake. Here, the plate with at least one printing ink printed. Important in the printing process is that the printing press is controlled so that the front plate edge always on the same Point enters the press, to a so-called "block formation", which leads to a Offset of the printed image comes to avoid. Also, the plate guided laterally at a fixed edge, around a reference edge for to have the finishing. The reference edge ensures a uniform plank width when later Divide the output plate into panels.

For decor printing, the panels are printed with a first printing ink. The order quantity is approx. 6 g / m ² . Preferably, a water-ink is used. The order of a second water-ink is possible. There is also the possibility of using a so-called Fugenzylinder instead of a second full-surface printing to emphasize the joints of a rod parquet optics or other decors optically. In principle, it is also possible to order a third water-based ink. Both the application of the second printing ink and the application of a third printing ink is carried out with an application rate of about 6 g / m ² .

To printing on the plate seals the printed surface. in principle can be said that the seal is made of a highly abrasion resistant and scratch-resistant sealing base layer, a so-called special ground, a sanding base and the application of topcoat in two or more Layers exists.

First, the sealant basecoat is applied in liquid form. This special lacquer contains substances which increase the abrasion resistance, in particular minerals such as corundum or corundum dust. The application of the sealer primer layer can be done in one or more operations and has a total application rate of 70-130 g / m ² . With multiple application of the sealer basecoat, the individual layers are gelled by ultraviolet light in a UV channel. Then a second order of the material is brought. This order is also gelled by UV radiation in a UV channel. Then a sand base, a so-called UV base in an application amount of about 12-30 g / m ^{2 is} applied, followed in turn followed by drying or fishing by means of UV radiation in a UV channel.

Different surface types or optics can be produced. In the case of a rolling structure, after the application of the sanding base, the topcoat coating takes place, wherein firstly a first layer of topcoat is applied with an application rate of between 6-15 g / m ² . The first topcoat is then gelled by means of UV radiation in a UV channel and provided with a second layer of topcoat with an application rate of between 4 and 10 g / m ² . The thus painted plate is then cured by means of UV radiation in a UV channel and divided into panels.

If a panel with a highly glossy surface is to be produced, a UV filler material is applied after application of the abrasive base, in an amount between 20 and 30 g / m ² . The UV scraper is then gelled by UV radiation in a UV channel and the skinned plate is again provided with a fine sanding. This is followed by the application of the topcoat with subsequent drying.

To produce a pore structure, the surface after the application of the 1st top coat layer be provided by means of a calender embossing roller with a structure which is pressed into the gelled paint. In this case, for example, a so-called universal wooden pore can be produced. The embossing roller is heatable. In the embossed mechanical pore, the second topcoat layer seals the embossing.

Alternatively, instead of a structured embossing, a pore printing ink with an application amount of between 4 g / m ² and 6 g / m ² can be applied to the first topcoat layer. The pore ink is applied to the gelled topcoat by means of an engraved roller. For the printed chemical pore, the second topcoat layer reacts with the pore ink, displacing the topcoat at the point where the pore ink was printed.

To the The lacquered plate ends with UV radiation in one Hardened UV channel and divided into individual panels.

Another variant consists in producing a lacquered pore appearance, for which purpose the second topcoat layer is applied by means of an engraved roller to the gelled topcoat layer with a printing machine, in an application quantity of 2 g / m ² to 10 g / m ² . In this case, pores can be printed both positively and negatively. This pore can be printed as a universal or synchronous pore. In order to emphasize the appearance and to achieve a clearly visible result, the topcoats have different gloss levels. When using a matte topcoat for the 1st Topcoat layer comes as a topcoat for the 2nd topcoat layer a glossy topcoat used or vice versa.

The curing The painted panels are then again using UV radiation in a UV channel, whereupon the plate in a subsequent operation is divided into panels.

The surface the panels are highly durable. It can Panels with different optics and gloss levels economically and rationally produced.

Claims (16)

Panel for floor, wall or ceiling coverings, which has a base plate, which is provided on its upper side with a decor and a seal, the base plate is ground on its underside with a backslash and the top of the base plate and provided with a primer, and a putty material is applied to the primer, characterized in that a base color coating is applied to the putty material and that on the base color coating, a color decoration is printed, which is provided with a sealant and a topcoat coating, which consists of a 1. Topcoat layer and a second topcoat layer exists. Panel according to claim 1, characterized in that that the base color coating is executed at least two layers. Panel according to claim 1 or 2, characterized that the color decoration is applied in one to three colors. Panel according to one of claims 1 to 3, characterized that the seal from a sealing base layer and a Sanding layer consists. Panel according to claim 4, characterized in that that applied to the abrasive base layer, a filler layer is. Panel according to one of claims 1 to 5, characterized in that a structure is introduced into the first topcoat layer. Panel according to one of claims 1 to 5, characterized in that a pore printing ink is applied to the first topcoat layer. Process for producing a panel, which is a Base plate has, on its top with a decor and a seal is provided, characterized by the following steps: a) Provision of a large plate from a compacted fiber material; b) on the underside the godfather becomes a watery backslash applied and dried; c) the top of the plate is sanded; d) then the top is primed and dried; e) then apply to the primer a putty applied and dried; f) what the application of a basic color coating with subsequent drying he follows; g) now the base color coating with at least printed on a printing ink; h) on the printing ink is a Applied primer coat, i) on the sealer basecoat a sanding base is applied; j) then a fine touch performed at the top; k) whereupon applied in several layers one or more topcoats become; l) then the plate is dried and m) then the Plate divided into panels. A method according to claim 8, characterized gekenn indicates that the base coat is made by a first coat of a base paint dried with hot air, followed by a second coat of base coat. Method according to claim 9, characterized that on the 2nd order of the base color a 3rd order with base color without intermediate drying and the two Basisfaben then dried become. Method according to one of claims 9 to 10, characterized that the primer, the putty material and the base color coating rolled on become. Method according to one of claims 9 to 11, characterized that one or more printing inks are applied. Method according to one of claims 9 to 12, characterized that after application of the abrasive base (measure i)) a UV filler material applied and dried by means of UV light. Method according to one of claims 9 to 13, characterized that a first topcoat layer and a second topcoat layer are applied, wherein after the order of the first topcoat layer irradiation of the Topcoat layer is carried out with UV light. Method according to claim 14, characterized in that the first topcoat layer is structured by means of an embossing roller. Method according to claim 14, characterized in that that the first top coat layer is provided with a pore printing ink.