DE102006024593B4 - floor panel - Google Patents

Abstract

Floor panel consisting of a medium-density fiberboard as a support plate (1) made of lignocellulosic material and a binder, with an upper cover layer (2), a middle layer (3) and a lower cover layer (4) and side edges (I, II, III, IV), wherein the carrier plate (1) for increasing the specific gravity contains mineral particles (5) which are heavier than the lignocellulose-containing material and the binder, characterized in that the proportion of mineral particles is 5 to 50%, the specific weight in a cover layer (2, 4) and the middle layer (3) is substantially constant and increases in the region of the opposite cover layer (4, 2) that the mineral particles (5) and the binder swelling protection agent are added.

Description

The Invention relates to a floor panel consisting from a carrier plate of lignocellulosic material and a binder, with an upper one Cover layer, a middle layer and a lower cover layer and Side edges, with the support plate to increase the specific gravity contains mineral particles that heavier than the lignocellulosic material and the binder.

The sound insulation of floor panels, especially laminate panels, are inferior compared to parquet. To the noise when walking on the floor To reduce, on the subfloor either insulating mats made of plastic, on which the panels are then placed, or it is factory already on the underside of the carrier plate an insulating layer applied.

By the necessary insulation layer will be an extra Layer applied to the panel and the floor construction becomes thicker and thicker heavier. For later Designing rooms with laminate panels, however, it is desirable that the panels are thin. On the other hand, the application of the insulating layer on the bottom requires the carrier plate another operation and additional material, what the Production costs increased. The Laying out an insulating foil on the subfloor must be done very carefully to one effective insulation to lead the footstep sound.

The DE 10 2005 045 043 A1 discloses a bottom construction of plates, wherein in the surface region of the plates, an additive is added to the material. This can for example consist of stone chips or limestone sand or marble Marble split to give the surface of the bottom plate the desired appearance.

The DE 74 26 809 U discloses floorboards to which, for example, quartz flour was added as an additive to improve the thermal conductivity. The floorboards described there are intended to be placed on a floor heating, so that a high thermal conductivity is important.

The DE 10 2005 034 856 A1 discloses unblended wood-based panels to which foreign materials, such as metals or recycled material, was added prior to compression. As a result, the decorative expression of the wood-based panel is improved.

In the EP 1 349 996 B1 discloses a sound insulating mat which can be applied to the underside of floor panels. The soundproofing mat contains heavy particles, for example made of chalk, to obtain a mat with an asymmetric density profile that has improved sound insulation properties. However, the laying of the soundproofing mat and the floor panel must continue to be carried out separately here, or an additional working step is required in which the soundproofing mat and the floorpanel must be connected to one another, for example via a cost-intensive adhesive. In addition, the particles are only insufficiently bound in the sound insulation mat so that they trickle out during the handling and processing of the sound insulation mats. The binding of the particles can be improved only by a high proportion of binder such as by the addition of glue or binder fibers, whereby the manufacturing cost of such mats are increased again.

From Starting from this problem, it is an object of the invention the floor panel described above to improve and reduce the manufacturing cost of soundproofing floor panels.

The Troubleshooting takes place in the generic floor panel in that the proportion of mineral particles or particles made of wood ash is 5 to 50%, that the specific gravity in a topcoat and the middle class is essentially constant and in the area of the opposite Topcoat increases that the mineral particles and the binders Swelling agents are added.

hereby There is a shift of perceived as disturbing frequencies in a deeper area when walking on a floor from carrier plates, in particular wood-based panels, felt in a disturbing Frequency band of 100 Hz to 14 kHz is formed. That's how it works through the increase the specific gravity of the plate by the addition of particles, which are heavier than the lignocellulosic material and the Binders that lower the resonant frequency of the floor panel. at an addition of 10% particles can be reduce the Resonanzfre frequency by about 3%. Will the addition of Increased particles, so the resonance frequency can be lowered further. Inventive plates with lowered resonant frequency are sluggish, sound deeper and swing longer. The plates according to the invention be as pleasant sounding perceived.

The proportion of heavy particles used to increase the specific gravity of the plate is 5 to 50%. By adding the heavy particles, the resonant frequency of the carrier plate can be lowered. Is closed by Zu If heavy particles increase the specific gravity of the carrier plate by about 10%, the resonance frequency can be lowered by about 3%. With a further increase of the specific weight and in particular by a special arrangement of the heavy particles, the resonance frequency can be lowered even further.

Around the moisture properties of the floor panel to improve both the particles and the binder further additives be added. In particular, swelling protection agents, which contribute to reducing the swelling and shrinkage dimensions of the floor panel.

The specific weight of the carrier plate increases over the cross section from one cover layer to the other cover layer. As a result, an asymmetric density profile is possible, which is necessary for the reduction of the resonance frequency of the floor panel and thus to improve the sound insulation properties, footfall and room sound, the floor. Advantageously, in this case the specific weight only increases in the region of a covering layer, so that in the remaining covering layer and in the middle layer the specific gravity of the plate is substantially constant. The specific weight of the carrier plate should be at least 350 kg / m ³ .

Around To obtain an asymmetric density profile, the heavy particles may be distributed only in the lower cover layer. It is also possible distribute the heavy particles only in the upper surface layer, also to obtain an asymmetric density profile. in this connection It should be noted that the top layer and middle layers are just like that be named to provide a precise description. Indeed There is a smooth transition between the cover layers and the middle layer. Layers in the sense of demarcated areas are not provided.

Become the particles in both the lower and upper cover layers and distributed in the middle class, turns to a symmetrical Density profile that with the conventional density profiles a carrier plate from lignocellulosic material, but more pronounced gross density maxima having in the outer layers.

It has been shown that it is advantageous to use a medium-density fiberboard as the carrier plate. However, it is also conceivable to use as carrier plates also chipboard or other fiberboard, for example, high density fiberboard. The specific weight of the support plate should be at least 350 kg / m ³ , so that the floor panel has sufficient strength properties.

The mineral particles that increase specific gravity the plate are used, in particular particles of chalk, Quartz sand, barium sulfate or barite.

Around the carrier plates lay as floor panels to be able to they are on opposite side edges provided with grooves and springs, with the locking elements for mechanical interlocking of floor panels with each other are provided. To protect the floor panel from wear and tear Optical design can be on the top cover with a decor be applied abrasion resistant layer. By the application of a De kors can various optical designs are realized on the carrier plate, so it is possible to Example wood surfaces to imitate or even apply stone or fantasy decors. To protect the decor from wear is above the decor a Abrasion-resistant layer, for example, abrasion resistant particles such as corundum may contain, applied. These measures can be the life of floor panels increase significantly.

Around the bowl behavior counteract unilaterally decorated and coated panels, can be applied to the lower cover layer a back-pull. Advantageously, both Decor as well as return from one or more layers of paper consist. The paper layers are applied to the before application support plate with a synthetic resin, z. B. with melamine resin, impregnated and then in a hot press with the carrier plate pressed.

Around the production of the floor panels according to the invention To further simplify decor and Gegenzug also from directly printed synthetic resin layers, eg. B. of melamine resin, exist. So, on individual paper layers, which impregnated in advance Need to become, be waived and the production costs can be further reduced.

advantageously, is the binder content of the carrier plate about 6 to 20%. As binders, urea-formaldehyde, Phenolformaldehyde, melamineureaformaldehyde, melamineureaphenolformaldehyde or PMDI resins used to achieve a good strength of the carrier plate.

In order to achieve a noticeable reduction in the resonant frequency, the specific gravity deviation in the average specific gravity cover layers in the middle layer should be at least 175 kg / m ³ or the specific gravity deviation in the middle specific gravity cover layers in the middle layer should be at least 50% of the specific Ge weight of the middle class. The specific gravity profile should be symmetrical about the center and substantially constant over a range of at least one third of the plate thickness.

• – Beleimen des lignocellulosehaltigen Materials mit einem Bindemittel und anschließendes Trocknen des beleimten Materials;
• – Streuung des beleimten Materials zu einer Fasermatte;
• – Aufstreuen von Partikeln, die schwerer sind als das mit dem Bindemittel beleimte lignocellulosehaltige Material, auf die Fasermatte und
• – Verpressen der Matte.

A method for producing a floor panel, in particular made of wood material, consisting of a support plate of lignocellulose-containing material and a binder having an upper cover layer, a middle layer and a lower cover layer and side edges is characterized by the following steps:

• - Gluing the lignocellulosic material with a binder and then drying the glued material;
• Scattering of the glued material to a fiber mat;
• Scattering of particles heavier than the lignocellulosic material glued with the binder onto the fiber mat and
• - pressing the mat.

• – Beleimen des lignocellulosehaligen Materials mit einem Bindemittel und anschließendes Trocknen des beleimten Materials;
• – Zugabe von Partikeln, die schwerer sind als das mit dem Bindemittel beleimte lignocellulosehaltige Material;
• – Streuung des beleimten Materials und der Partikel zu einer Fasermatte und
• – Verpressen der Matte.

Another method for producing a floor panel is characterized by the following steps:

• - Gluing the lignocellulosic material with a binder and then drying the glued material;
• Addition of particles heavier than the binder-coated lignocellulosic material;
• Scattering of the glued material and the particles into a fiber mat and
• - pressing the mat.

On that way the glue consumption, which for producing a floor panel with an asymmetric density profile is necessary, significantly reduce because the heavy particles are not glued with a binder have to. hereby can reduce the production costs. It is also possible that heavy particles either to the fibers for the upper surface layer or the Add lower cover layer. So can be selected in advance, whether an increased Raw density can be realized on the top or bottom of the plate should. By adding the heavy particles to the fibers of the top and the lower cover layer may be a plate having extreme raw density maxima be generated in the outer layers.

• – Zugabe von Partikeln zum lignocellulosehaltigen Material für die untere Deckschicht, die schwerer sind als das lignocellulosehaltige Material;
• – Beleimung des lignocellulosehaltigen Materials und der schweren Partikel für die untere Deckschicht;
• – Beleimung des lignocellulosehaltigen Materials für die Mittelschicht und für die obere Deckschicht;
• – Trocknen des beleimten, lignocellulosehaltigen Materials;
• – Streuung einer Matte mit unterer Deckschicht, Mittelschicht und oberer Deckschicht und
• – Verpressen der Matte.

Another method for producing a floor panel is characterized by the following steps:

• Adding particles to the lignocellulosic material for the lower cover layer which are heavier than the lignocellulosic material;
• - gluing the lignocellulose-containing material and the heavy particles for the lower cover layer;
• Gluing of the lignocellulosic material for the middle layer and for the upper cover layer;
• - drying the glued, lignocellulosic material;
• Scattering of a mat with lower cover layer, middle layer and upper cover layer and
• - pressing the mat.

• – Zugabe von Partikeln zum lignocellulosehaltigen Material für die obere Deckschicht, die schwerer sind als das lignocellulosehaltige Material;
• – Beleimung des lignocellulosehaltigen Materials und der schweren Partikel für die obere Deckschicht;
• – Beleimung des lignocellulosehaltigen Materials für die Mittelschicht und für die untere Deckschicht;
• – Trocknen des beleimten, lignocellulosehaltigen Materials;
• – Streuung einer Matte mit unterer Deckschicht, Mittelschicht und oberer Deckschicht und
• – Verpressen der Matte.

Another method for producing a floor panel is characterized by the following steps:

• Addition of particles to the lignocellulosic material for the top layer, heavier than the lignocellulosic material;
• - gluing the lignocellulosic material and the heavy particles for the upper surface layer;
• - gluing the lignocellulosic material for the middle layer and for the lower cover layer;
• - drying the glued, lignocellulosic material;
• Scattering of a mat with lower cover layer, middle layer and upper cover layer and
• - pressing the mat.

By This method can reduce the specific gravity of the carrier plate elevated to lower the resonance frequency of the floor panel and the sound insulation properties such as step and room sound insulation properties of the floor panel to improve.

ever after how the density profile of the carrier plate is changed should, can the heavy particles to the lignocellulosic material of the lower Cover layer and the middle layer are added or the addition the heavy particle is added to the lignocellulosic material the upper cover layer and the middle layer. It is also possible that heavy particle only to the lignocellulosic material of a Add cover layer. This also achieves an asymmetrical density profile.

Should the carrier plate have a symmetrical density profile, the addition takes place the heavy particle to the lignocellulosic material of the upper Cover layer, the middle layer and the lower cover layer.

It has been shown that it is advantageous to add the heavy particles in the gluing of the lignocellulosic material. In this case, mineral particles, in particular chalk, quartz sand, barium sulfate, barite or wood ash may be added as particles. As lignocellulosic material wood fibers are used. But it is also possible to use wood chips as lignocellulosic material.

The Pressing the glued lignocellulosic material and the Particles can be used in continuous or discontinuous hot presses carried out under temperature and pressure. Due to the im Comparison to the lignocellulosic material different Heat absorption capacity of the heavy Particles may be required to withstand the pressing times Press times of conventional Carrier plate making, in particular the wood-based panel manufacturing to change.

following to an exemplary embodiment of the invention with reference to a drawing be explained in more detail. Show it

1 - An enlarged detail of the cross section of a floor panel;

2 - the cross section of a floor panel;

3 - The density profile of a floor panel and

4 - The top view of a floor panel.

1 shows the floor panel with a support plate 1 made of wood fibers and a binder as well as particles 5 consists of increasing the specific weight in the carrier plate 1 are stored. The particles 5 are in the middle class 3 and in the area of the lower cover layer 4 distributed. The concentration of the particles 5 is here in the range of the lower cover layer 4 larger than in the middle class 3 , The particles 5 are made of chalk and have a specific weight of 2930 kg / m ³ . The particle content in the carrier plate 1 is 50%. As a binder PMDI resin is added in a proportion of 6%.

2 shows the cross section of a floor panel consisting of a support plate 1 with an upper cover layer 2 , a middle class 3 and a lower cover layer 4 , In the lower cover layer 4 as well as in the middle class 3 are heavy particles 5 distributed. By locally increasing the specific weight of the carrier plate 1 the weight of the plate is locally increased and a lowering of the resonance frequency can be achieved. The footfall and room sound insulation properties of the floor panel are thereby improved. The carrier plate 1 has side edges II and III on. At the side edge II is a groove 6 and on the side edge III is a spring 8th educated. The connecting means serve to connect a plurality of floor panels with each other.

3 shows the density profile 10 of the floor panel. Due to the addition of particles 5 into the middle class 3 and in the lower cover layer 4 the carrier plate 1 (see 1 ) is the density profile 10 asymmetric with a maximum of specific gravity in the area of the lower cover layer 4 , The difference between the specific gravity in the lower cover layer 4 and the middle class 3 is at least 175 kg / m ³ . The difference in specific gravity between the topcoat 2 . 4 and the middle class 3 in this case is 50% of the specific weight of the support plate 1 ,

4 shows the top view of the floor panel. The floor panel has at its side edges I . II . III and IV Connecting means for connecting a plurality of floor panels with each other. These are on the side edges II and IV groove 6 and 9 molded and on the side edges I and II feathers 7 and 8th educated.

1

support plate

2

Upper topcoat

3

middle class

4

Lower topcoat

5

particle

6

groove

7

feather

8th

feather

9

groove

10

ply construction

I

side edge

II

side edge

III

side edge

IV

side edge

Claims (15)

Floor panel consisting of a medium-density fiberboard as a support plate ( 1 ) of lignocellulose-containing material and a binder, with an upper covering layer ( 2 ), a middle class ( 3 ) and a lower cover layer ( 4 ) and side edges ( I . II . III . IV ), wherein the support plate ( 1 ) for increasing the specific gravity of mineral particles ( 5 ), which are heavier than the lignocellulosic material and the binder, characterized in that the proportion of mineral particles 5 to 50% is that the specific gravity in a top layer ( 2 . 4 ) and the middle class ( 3 ) is substantially constant and in the region of the opposite outer layer ( 4 . 2 ) increases that the mineral particles ( 5 ) and the binder swelling agent are added. Floor panel consisting of a medium-density fiberboard as a support plate ( 1 ) from lignocel lulosehaltigem material and a binder, with an upper cover layer ( 2 ), a middle class ( 3 ) and a lower cover layer ( 4 ) and side edges ( I . II . III . IV ), wherein the support plate ( 1 ) to increase the specific gravity contains particles of wood ash, which are heavier than the lignocellulosic material and the binder, characterized in that the proportion of particles of wood ash 5 to 50% is that the specific gravity in a top layer ( 2 . 4 ) and the middle class ( 3 ) is substantially constant and in the region of the opposite outer layer ( 4 . 2 ) increases that the particles of wood ash and the binder swelling protection agent are added. Floor panel according to claim 1 or 2, characterized in that the mineral particles ( 5 ) or the particles of wood ash in the lower cover layer ( 4 ) are distributed. Floor panel according to claim 1 or 2, characterized in that the mineral particles ( 5 ) or the particles of wood ash in the upper cover layer ( 2 ) are distributed. Floor panel according to claim 1 or 2, characterized in that the mineral particles ( 5 ) or the particles of wood ash in the lower and the upper cover layer ( 2 . 4 ) and in the middle class ( 3 ) are distributed. Floor panel according to claim 1, characterized in that the mineral particles ( 5 ) of chalk, quartz sand, barium sulfate or barite. Floor panel according to one or more of the preceding claims, characterized in that the side edges ( II . IV ) Grooves ( 6 . 9 ) and the side edges ( I . III ) Feathers ( 7 . 8th ), which are provided with locking elements for mechanical locking of the panels with each other. Floor panel according to one or more of the preceding claims, characterized in that on the upper cover layer ( 2 ) a decor is applied with an abrasion-resistant layer. Floor panel according to claim 8, characterized in that on the lower cover layer ( 4 ) a return is applied. floor panel according to claim 9, characterized in that decor and return consist of one or more layers of paper. floor panel according to claim 9, characterized in that decor and return consist of directly printed synthetic resin layers. floor panel according to one or more of the preceding claims, characterized by a binder content of 6 to 20%. floor panel according to claim 12, characterized in that the binder is a Urea-formaldehyde, phenolformaldehyde, melamine-urea-formaldehyde, Melamine urea phenol formaldehyde or PMDI resin. Floor panel according to claim 1 or 2, characterized in that the difference in specific gravity between the cover layer ( 2 . 4 ) and the middle class ( 3 ) is at least 175 kg / m ³ . Floor panel according to claim 14, characterized in that the difference of the specific weight between the cover layer ( 2 . 4 ) and the middle class ( 3 ) at least 50% of the specific gravity of the carrier plate ( 1 ) is.