DE102007054516A1 - Method for producing a floor covering plate - Google Patents

Abstract

The invention relates to a method for producing a floor covering plate comprising the following steps: providing a base plate with a natural surface of wood or cork, placing a protective layer on the natural surface, pressing an elastic auxiliary layer against the protective layer and thereby pressing the protective layer against the natural surface, so that the protective layer substantially assumes the surface structure of the natural surface, and the invention relates to a correspondingly produced floor covering plate.

Description

The The present invention relates to a method for producing a Flooring panel with a protective layer on a base plate is applied to the floor covering against abrasion and others Damage caused by the intended use Passing such a floorboard may occur. The invention also relates to a floor covering plate with a protective layer as well as a flooring that is made of a variety such floorboards is composed.

Flooring plates are well known. They are used with others Flooring panels to be assembled into a floor covering. These include, for example, laminate plates or plates for creating a finished parquet floor.

In a variant consists of a floor covering plate of several layers, one of which is an HDF plate. The HDF plate essentially serves as Carrier material and to, the desired stiffness to reach the floor covering plate. Often there are more layers intended for stabilization or soundproofing. As as arranged thereon cover layer can be a layer with egg nem design Be provided to the floor covering plate and thus to be created Flooring to give an attractive appearance.

Often however, an artificial design is undesirable and the flooring panel is rather the impression of a natural product convey. In particular, the impression of wood is often Cork desired. For cost reasons, this is often used a multi-layer flooring panel at the only one top, thin layer of the respective Natural product is arranged. Such a thin layer, So in particular a thin wood or cork layer is but not very durable and needs a protective layer, for use, namely, in particular, a permanent one Inspection by persons to be able to withstand.

A known variant for producing a protective layer is to apply a protective lacquer. However, such a lacquer layer provides only a limited resistance, so that the floor covering plate has only a low load class and can be used appropriately only in rooms with low load. According to the classification of resilient floor coverings EN 685 lacquered cork flooring can be used for a maximum load class of 23/31. Cork floor coverings with a PVC protective layer can be used up to a load class of 33/42.

A such PVC protective layer as a protective layer is thereby in the production glued on a natural layer and then by pressing permanently attached. This has led to the surface the protective layer is smooth and flat and this is the desired Effect of the impression of a natural plate has impaired.

Other Methods have pursued the approach of using special press plates, the one negative surface contour with the respectively desired Have pattern. However, such press plates are only able to always apply the same pattern. A flooring consisting of Such Bodenbelagsplat th thus has recurrent patterns on. In addition, special press plates must be made and be changed accordingly when changing the product.

task Thus, the present invention addresses the above problems as possible to reduce or remedy. In particular, lies The present invention has the object, a method for Creating a flooring plate to create the one possible has a natural appearance and a durable Surface has a natural surface texture as possible. Likewise, the invention has the object, a corresponding Flooring plate and provide a corresponding floor covering.

According to the invention Thus, a method according to claim 1 is proposed.

Consequently First, a base plate is provided, the one Natural surface has. In particular, this natural surface made of wood or cork. Accordingly, the natural surface also a surface structure, such as from Wood or cork is known. Such a surface structure arises in particular when a wood veneer or cork veneer is used.

On a protective layer is then arranged on such a surface. Such a protective layer is a hard-wearing Fabric, such as a piece of plastic web or foil or the like on the natural surface is glued on. The claimed protective layer is clearly in this case different from a protective varnish or other, liquid applied material that is already in the application in wells of a Surface structure sets. The protective layer is rather in the solid state as a flat sheet, plate or the like placed the natural surface and then in the first Essentially of raised areas of the structure of the natural surface carried.

On the protective layer is then at an off design the elastic auxiliary layer. The term "up" refers to an orientation of the flooring panel to be manufactured which corresponds to the orientation of the later intended use In principle, the flooring panel could also have a different orientation in the manufacturing process or in at least one or a few steps of the manufacturing process, e.g. The protective layer is below.

To This step is then in this embodiment, a stack before, at least from the base plate, the protective layer and the elastic auxiliary layer consists. This stack is then pressed by means of two pressing tools, between which this stack is arranged, compressed. in this connection a lower pressing tool is used as a counter-plate, this Stack against the pressure of the second pressing tool holds. This second pressing tool presses the auxiliary layer against the protective layer. The protective layer is initially against the natural surface and thus against the raised areas of the structure surface pressed. At these points thus builds a back pressure on, with the protective layer presses against the auxiliary layer and the movement of the auxiliary layer at this point in the pressing direction counteracts. Due to its elasticity, the auxiliary layer gives way However, the counterpressure at the sublime sites and thus able the protective layer also in the deeper areas of the surface structure to squeeze.

at another embodiment is the elastic auxiliary layer arranged on the pressing tool.

Because the described compensation process substantially in the auxiliary layer takes place and not or at least only partially in the protective layer, not only does the protective layer lie in the recesses of the structure, Rather, it essentially takes the surface structure in their entire thickness. Ie. the surface structure the natural surface is also on the side of the Protective layer which faces away from the natural surface and to the auxiliary layer has.

To the pressing, so after or with the removal, at least one the pressing tools, the auxiliary layer is removed. Due to the Elasticity of the auxiliary layer returns this after the pressure the pressing tools were released again, essentially back to its previous form. The auxiliary layer thus dissolves from the depressions, which presses have arisen on the corresponding side of the protective layer. Furthermore the auxiliary layer essentially regains its level and just form that she had before pressing and can thereby for the next pressing process for the next Flooring panel to be reused. This next one Flooring panel may differ from the previous one and usually it will be different, since even the natural surfaces from one floorboard to the next, at least in detail be different.

According to one Embodiment will be composed of several base layers Plate and the natural surface through a wooden or Cork veneer layer formed. Such a wood or cork veneer layer is cut from a piece of wood or cork and optionally composed of several pieces and forms one relatively thin layer from the relevant natural material. This veneer layer thus creates a natural surface of the actual natural material, without needing much of the natural material. By using the actual natural material receives every flooring sheet produced has its own individual look. Such veneer layers of natural material are themselves less resistant. The resistance is achieved by the invention Arranging a protective layer is achieved, at the same time the surface structure the veneer layer on the surface of the protective layer.

at Use of a transparent protective layer receives one Flooring panel thus in its surface the appearance a natural product and at the same time essentially the surface structure the visible natural surface with simultaneous creation a protective layer with a high load capacity.

Cheap is to use a base plate with at least one HDF layer. Under a HDF layer, this is a "high density Fiberboard "layer understood Chipboard or a plywood board are used. Such Wood layer is basically known and simple and inexpensive manufacture. The wood layer provides a good, stable base for the base plate. Usually, such a wood layer about 6-10 mm, in particular about 8 mm thick. Cheap it is when the manufacturing process of the floorboard is the Assembling the base plate from the base layers includes. One Such composing usually takes place before the Protective layer is applied.

Preferably, an elastic plastic sheet is used as an elastic auxiliary layer to achieve good elasticity properties and high durability, in particular a high number of application cycles. Preferably, the plastic plate is heat resistant to withstand the heat during the pressing process can. In particular, should the plastic plate or other auxiliary layer in their heat resistance to the press in particular, and retain their elasticity even during the heat during the pressing process, and in particular, no thermal deformation should occur.

Preferably the auxiliary layer has a thickness of 1-10, preferably 1-5 and in particular about 2 mm. The thickness of the auxiliary layer should be much thicker than the depth of the surface structure, so that the auxiliary layer performs the balancing operations described above can perform. From the use of a too thick auxiliary layer should, however, for reasons of efficiency and cost reasons be disregarded.

When Protective layer is preferably used a PVC layer. Such PVC layer has proven to be durable and is Total as a material for a flooring for many years tested. By the method according to the invention In this case, a floor covering plate can be created that the durability a PVC coating and thereby - at least when using a transparent PVC layer - the look and a Surface structure of a natural product has.

Preferably the pressing is carried out so that a pressing tool with a substantially flat pressing surface against the auxiliary layer is pressed. This can be a uniform pressing be reached on the floor covering plate. in principle Also, a press roll can be used to place it under substantially constant pressure over the auxiliary layer, However, care must be taken that no shift the individual layers or layers against each other. This can be achieved by using the auxiliary layer, because This avoids direct rolling over the protective layer becomes.

According to the invention also proposed a floor covering plate with a Base plate, a wood or cork veneer layer arranged thereon with a natural surface with a natural surface structure and a PVC protective layer arranged thereon, characterized that the PVC protective layer facing away from the natural surface Site essentially the surface structure of the natural surface having. As a result, a floor covering plate is created, the at least visually and haptically with regard to their user surface a natural wood or natural cork board is adjusted. simultaneously will have a high resistance to the surface created this flooring panel. Preferably, such Flooring panel with a method, at least according to one the embodiments of the invention.

According to one Embodiment, the floorboard has a base plate which consists of at least one HDF board, a wooden or cork veneer layer and an insulating layer, in particular made of cork, which is on the side facing away from the PVC layer side of the bottom plate is arranged. Thus, a simple and inexpensive to produce base plate with at the same time a visual and tactile attractive and durable surface provided.

Prefers has a floor covering plate seen from top to bottom on a PVC protective layer, the durability of the surface of the floorboard should reach. Such a PVC protective layer has a strength of about 0.3-0.5 mm, especially about 0.4 mm. The PVC protective layer is applied directly to a wood or cork veneer layer. The wood or Korkfurnierschicht serves to the floor covering plate to provide a similar look. At the same time this wood or cork veneer layer the surface structure ready, which essentially adopts the PVC protective layer. The wood or cork veneer layer may have a thickness of about 0.4-0.8 mm, in particular 0.5 mm. It is used as a wood or cork veneer layer a high quality material used to make a corresponding desired optical appearance of the surface to reach the floor covering plate.

The Wood or cork veneer layer is applied on a cork layer as a carrier layer arranged. This cork layer as a carrier layer can be a Thickness of about 2 mm. For this is pressed cork used. Such cork is usually made of crushed, Pressed with cork corked. Such a press cork layer among other things, a certain elasticity for reach the floor covering plate and also can the emergence and transfer prevent or reduce impact sound.

The Cork layer as a carrier layer is on an HDF layer arranged as a main carrier plate, which in turn on a lower wooden counter can be arranged. Here, the HDF layer forms the Main carrier plate or carrier layer with a thickness in the order of 8 mm. Such a HDF plate is essentially made of wood fibers, which together with a binder is pressed to a plate or layer. A such HDF plate is relative hard, but especially against tensile loads and thus too reinforced against bending stresses by a wooden cover become. Such a wooden counterweight essentially has a strength of about 0.8 mm and is made of real wood, but one may have low quality.

Under the HDF board, or - if available - under the lower wooden counterpart under the HDF plate is finally another layer of press cork arranged. This essentially has one Thickness of 2 mm and is as impact sound insulation, So to reduce the resulting when walking the floorboard Trittgeräusches provided. This press cork layer, conditional Due to the flexibility of the cork, smaller bumps are also used in the subsoil balance. Without the cork layer would have Mandatory another footfall sound insulation of the floor covering plate be laid on the subfloor. Sometimes both the cork layer as impact sound insulation as well as the cork layer as a carrier layer be saved for the wood or cork veneer layer. In particular if the floorboard has a cork veneer layer, the lower wooden counterpart is dispensable.

The Manufacturing process of such a floor covering plate is usually done so that first the HDF disk - or other Wooden plate - is provided. Subsequently is the wood or cork veneer layer with the cork layer of press cork as Carrier material pressed and glued. The resulting two-layer plate is then pressed with the HDF plate and bonded. Before or after the HDF plate with the wooden counterpart - if available - provided. Next is the footfall sound insulation pressed from pressed cork on it and glued.

The thus made including the wood or cork veneer layer Plate falls under the name "base plate". On this base plate and thus on the wood or veneer layer then takes place the arrangement of a transparent PVC layer, the as already described further provided with an auxiliary layer and then crimping with the base plate to achieve that the protective layer into the structure of the wood or cork veneer layer places and these due to the elastic auxiliary layer on its top at least partially accepted. Subsequently, the auxiliary layer be removed and the flooring plate is with regard to their Layers completed. It may still be a cropping of Connect flooring plate and it still can with groove and spring are provided to make it out of several flooring panels In a simple way a floor covering can be produced.

The In addition, protective layer can in turn consist of two layers be made. One layer will be on the wood or cork veneer layer applied and creates in particular the surface hardness, for a special resistance of the surface the floor covering plate is provided. On this especially hard Layer can be applied to another layer, for example, good Has cleaning properties and compensates for differences in gloss, which can occur during hot pressing of the PVC layer. For example, it becomes a very matt surface with a degree of gloss Made from 10% -15% to keep the look as natural as possible to design.

• a. eine PVC-Schutzschicht,
• b. eine Presskorkschicht, und
• c. eine PVC-Schicht.

According to a further embodiment, a floor covering plate can be produced, which is provided for manufacturing a permanently laid floor covering. Such a floor covering plate, when laid from top to bottom as intended, has the following layers:

• a. a PVC protective layer,
• b. a cork layer, and
• c. a PVC layer.

A Such floorboard is usually with its lower Glued PVC layer on a floor, such as a screed floor for installation. The press cork layer and the lower PVC layer thus form the Baseplate. On the press cork layer is in a simple embodiment a transparent PVC protective layer arranged so that the cork layer is visible. Other versions are on the press cork layer arranged a cork or wood veneer layer, so that laid in the Condition is visible. All of these firmly laid Flooring panels can have a thickness of 3-6 mm, preferably 3.2 mm. These floor tiles also usually have on the PVC protective layer yet another protective layer, in particular a protective lacquer, as already mentioned above in connection with others Embodiments has been described.

Such Flooring panels for fixed installation are therefore also to produce according to the invention and have a durable surface, where a natural surface is visible and where too a structure according to the natural surface emerges on the surface of the protective layer. At least In that regard, an improvement over previously known Vinyl flooring can be achieved.

According to one example, a highly refined silicone layer is used as auxiliary layer. This silicone layer is transparent and has a density of 1.2 g / cm ³ . The Shore hardness (ASTM D 2240) is 50 +/- 5, it can also z. The ultimate tensile strength (ASTM D 412 C) is 9 Mpa, the elongation at break (ASTM D 412 C) is 650% and 400% after four hours of compression at 200 ° C, the tensile strength (ASTM D 624 B) is 40 kN / m or 35 kN / m after four hours of compression at 200 ° C. Compression after 22 h at 177 ° C is less than 50%. The range of application of this material is between -40 ° C and + 210 ° C. Such a material is available, for example, from "Ammeraal Beltech" entitled SI PLATINUM CURED TRANSPARENT 240 / PLT 2 mm.

The Invention will be described below with reference to two embodiments explained in more detail with reference to the accompanying figures, of which

1 describes the construction of a floor covering plate with a cork veneer layer and

2 describes a floor covering panel with a wood veneer layer.

According to 1 is the flooring plate 1 on the bottom with an integrated insulating cork underlayer 2 Mistake. On this cork underlayer 2 is an HDF plate 4 arranged. The 1 shows the individual layers with a distance between them, which serves only the better representation and makes the layers better recognizable. In fact, however, are in a finished floorboard 1 all layers without space on each other.

On the HDF plate 4 is a press cork layer 6 arranged for impact sound insulation and to support the cork veneer layer 8th serves. The cork veneer layer 8th has a natural surface 9 made of cork. Only the cork veneer layer 8th has a natural surface 9 made of cork with a large structure corresponding to a piece of cork or several cork pieces. The lower cork layer 2 as well as the middle cork layer 6 are each layers of pressed cork and therefore have no natural surface as the natural surface 9 made of cork, but rather reveal a variety of small cork pieces. However, if desired, a surface of a cork layer of pressed cork could also be used as the optical surface for a floor covering plate. The use of a natural surface 9 as in 1 presented, however, gives a much higher quality impression. On the cork veneer layer 8th and thus on their natural surface 9 is a protective layer 10 applied, which creates a high resistance to wear on the surface while maintaining the structure of the natural surface 9 accepts. On this protective layer 10 is another protective layer 12 arranged with further protection properties in particular against contamination. Manufacturing technology is the protective layer 10 on a base plate 14 arranged and pressed with the aid of an auxiliary layer to the structure of the natural surface 9 to accept. The base plate is formed here from the lower cork layer 2 , the HDF plate 4 , the insulating cork layer 6 and the cork veneer layer 8th , After the protective layer 10 on the base plate 14 is fixed, the (not shown) auxiliary layer is removed and it may eventually the protective layer 12 be applied. In the 1 is also the arrangement of groove 16 and spring 18 to recognize. Usually tongue and groove are milled both on the longitudinal and the transverse edges.

From the 2 is a floor covering plate 51 to recognize the one cork underlayer 52 and on it a wooden counterpart 53 having. Such a wooden counterpart 53 This is in comparison to the structure of the floor covering plate 1 of the 1 additionally available. On the wood tag 53 is then an HDF disk 54 with groove 66 and spring 68 arranged. The HDF plate 54 in turn carries on it a cork layer 56 , On it is the wood veneer layer 58 with its natural surface 59 arranged. The nature surface 59 finally gets through the protective layer 60 and additionally the protective layer 62 protected. The base plate 64 exists at the floor covering plate 51 according to 2 accordingly from the cork underlayer 52 , the wooden counterpart 53 , the HDF plate 54 , the press cork layer 56 and the wood veneer layer 58 ,

In the two embodiments according to 1 and 2 thus becomes a floor covering plate 1 respectively. 51 created, the optically a natural surface 9 made of cork or a natural surface 59 made of wood. These natural surfaces 9 respectively. 59 be through the protective layer 10 and the protective layer 12 respectively. 60 and 62 protected by the protective layer 10 and protective layer 12 respectively. 60 and 62 the natural surface 9 respectively. 59 can be seen through and is also evident in its contour.

QUOTES INCLUDE IN THE DESCRIPTION

This list The documents listed by the applicant have been automated generated and is solely for better information recorded by the reader. The list is not part of the German Patent or utility model application. The DPMA takes over no liability for any errors or omissions.

Cited non-patent literature

• - EN 685 [0005]

Claims (17)

Method for producing a floor covering plate comprising the steps: Provide a base plate with a natural surface of wood or cork, arranging a Protective layer on the natural surface, Pressing one elastic auxiliary layer against the protective layer and thereby pressing the protective layer against the natural surface, so that the protective layer essentially the surface structure of the natural surface and removing the auxiliary layer from the protective layer. The method of claim 1, wherein the elastic auxiliary layer is placed on the protective layer before pressing. Method according to claim 1 or 2, characterized that as a base plate composed of several base layers Plate is used, and the natural surface through a wood or Korkfurnierschicht is formed. The method of claim 3, wherein the base plate at least one HDF layer, a chipboard or a plywood board and / or the method comprises assembling the baseplate from the base layers. Method according to one of claims 1-3, wherein the base plate is a pressed cork layer and at least one PVC layer having. Method according to one of the preceding claims, characterized in that as elastic auxiliary layer an elastic Plastic plate is used, in particular a heat-resistant plastic plate. Method according to one of the preceding claims, characterized in that the auxiliary layer has a thickness of 1-10 mm, preferably 1-5 mm and in particular about 2 mm Method according to one of the preceding claims, characterized in that the auxiliary layer has a Shore hardness according to ASTM D 2240 in the range of 20-80, in particular 45-55 having Method according to one of the preceding claims, characterized in that used as a protective layer, a PVC layer becomes. Method according to one of the preceding claims, characterized in that the pressing carried out so becomes that a pressing tool having a substantially flat pressing surface is pressed against the auxiliary layer. Flooring board with a base plate with a Wood or cork veneer layer with a nature surface with natural surface structure and a arranged thereon PVC protective layer, characterized in that the PVC protective layer facing away from the natural surface Side essentially a surface texture accordingly having the surface structure of the natural surface and / or according to one of the methods of the preceding claims is made. Floor covering panel according to claim 11, characterized the baseplate is composed of at least one HDF layer, one Wood or cork veneer layer and an insulating layer, in particular made of cork, which is on one side of the base plate facing away from the PVC layer is arranged. Flooring panel according to claim 11 or 12, which when laid as directed from above below has the following layers: a. a PVC protective layer, b. a wood or cork veneer layer, c. a cork layer as Carrier layer for the wood-cork veneer layer d. an HDF layer as the main support plate, e. a thin one Wood layer as a lower wooden counterweight and f. a cork layer as impact sound insulation. Floor covering panel according to claim 13, which is intended Laying under the HDF layer - a thin one Wood layer as a lower wooden counterweight and / or - one Cork layer has as impact sound insulation. Floor covering plate according to claim 11, when intended Laying from top to bottom following layers: a. a PVC protective layer, b. a cork layer, and c. a PVC layer. Floor covering according to claim 15, further comprising a Cork or wood veneer layer between the PVC protective layer and the press cork layer. Flooring consisting of a large number of floor tiles according to any one of claims 11-16.