DE102013101795A1 - Support plate for planar components for e.g. furniture, has multiple plate-shape wood plastic compound layers made of WPC material that comprises filler offset plastic base material, and decoration layer incorporating timber veneer - Google Patents

Abstract

The plate has multiple plate-shape wood plastic compound (WPC) layers (2, 4, 6, 8) made of a WPC material that comprises a filler offset plastic base material. The WPC layers comprise different expansion behavior in the longitudinal and transverse direction of the plate. Adjacent WPC layers are arranged with respect to the longitudinal or transverse offset, where each of WPC layers is formed with a density gradient. A decoration layer comprises a wear layer and a clear coat. The decoration layer incorporates a timber veneer.

Description

The invention relates to a support plate for sheet-like components, for example for floor coverings, furniture, facades, etc.

Apart from solid parquet, it is customary to carry out floor coverings with a decorative layer, for example made of wood or a printed film, which is arranged on a supporting layer. On the underside, a so-called Gegenzugschicht is often applied to this support layer to improve the dimensional stability of the floor covering. The base layer may consist of HDF / MDF boards, the disadvantage of which is that even with an impregnation they have only an insufficient water resistance and thus the application is limited to the indoor area.

As a base layer and plywood panels can be used, but in terms of water resistance tend to have worse properties than the aforementioned HDF / MDF panels.

A laminate floor with an HDF / MDF support plate is for example in the DE 20 2007 018 998 U1 explained. In the WO 2010/145 766 A1 a laminate floor is described in which a wear layer is formed by a non-PVC-containing elastic film layer.

In these solutions HDF / MDF boards are used, which have the disadvantages explained above.

In contrast, the present invention seeks to provide a support plate for sheet-like components with improved water resistance and simple structure.

This object is achieved by a support plate having the features of claim 1.

Advantageous developments of the invention are the subject of the dependent claims.

According to the invention, the support plate is designed to apply thereto a decorative layer or a wear layer and can in principle be used for furniture, wall, ceiling or floor coverings and the like in indoor and outdoor areas. The support plate is designed as a layer structure, wherein a plurality of layers of a WPC material (Wood Plastic Compound) exist. Such a WPC material has a plastic base material, for example consisting of polypropylene, PVC, ABS, vinyl acetate, EVA or other plastics, which is mixed with a filler. A single WPC layer of a support plate according to the invention in the longitudinal and transverse direction of the plate has a different expansion behavior. This expansion behavior is preferably dependent on the temperature and / or the humidity. Longitudinal and transverse directions are understood as meaning two directions approximately perpendicular to one another within a plane of the plate.

The layer structure is chosen such that the layers are offset with respect to each other with respect to the longitudinal and transverse directions in which a different expansion behavior exists.

This staggered arrangement of the regions of greater or lesser extent creates an optimum in terms of strength base plate material that can be used due to its high water and temperature resistance both indoors and outdoor applications.

In one embodiment of the invention, it is preferred if the offset is about 90 °.

The teaching according to the invention is particularly well-suited for a WPC material whose filling material consists of fiber material, with each plate having a preferred fiber direction, so that the fiber orientation in adjacent layers is correspondingly offset.

Such WPC materials can be processed, for example, by extrusion, injection molding or calendering. For plate-shaped components, the production is preferably carried out by extrusion or calendering.

Such a WPC layer may be designed with a density gradient, wherein the density increases towards a large area of the layer.

The support plate can be designed with a decorative layer.

On the support side, a suitable nonwoven layer can be provided to improve the support on the ground.

For example, to improve the sound insulation, a heavy foil or a nonwoven layer can be provided between individual layers.

The support plate according to the invention can be used for example in furniture, for floor tiles, floor panels and sports floors both indoor and outdoor.

The watertight barrier between the individual layers is optimal if they are provided over the entire surface with a glue, for example based on PUR or the like. Also, a use in housing construction, for example, for formwork panels is possible because they must be made water resistant.

Alternatively, however, the layers may also be joined by welding, gluing or another suitable joining method.

In one embodiment of the invention, the decorative layer is executed with a wood veneer.

According to the invention, it is also possible that at least one veneer layer is provided in addition to the said WPC layers.

To increase the bending stiffness and the compressive strength, the support plate can also be designed with at least one fiber-reinforced layer, for example of a glass fiber or carbon fiber material.

A preferred embodiment of the invention will be explained in more detail below with reference to schematic drawings. Show it:

1 a schematic diagram of individual layers of a support plate according to the invention and

2 a suitable for a floor panel support plate.

The support plate described below 1 consists of a large number of WPC layers 2 . 4 . 6 . 8th which each have the same structure in this embodiment. The basic structure of such a WPC layer is in the WO 2011/006918 A1 explained. Accordingly, there is a WPC layer of a plastic base material, in most cases polypropylene, ABS, EVA, vinyl acetate or PVC, the latter being increasingly replaced by other types of plastic due to the plasticizer content and the disposal problem. This plastic is mixed with a filler which preferably fibers, here preferably natural fibers such as wood, paper, etc. glass fibers, textile fibers, etc. included. Furthermore, suitable additives are added, such as mineral fillers, flame retardants and other substances to ensure certain material properties.

As explained, the plate-shaped layers are preferably produced by extrusion or calendering. In this case, the material is "pulled" in a preferred direction, so that shrinkage or longitudinal expansion takes place longitudinally and transversely during relaxation. For fiber materials this is accompanied by a preferred fiber orientation.

As a result, conventional WPC layers have inhomogeneous expansion behavior along and across the fiber or machine direction (extrusion, calendering).

For components that require a homogeneous expansion behavior, such WPC plates are therefore not usable. Solutions are known in which one uses a plywood plate instead of a WPC plate. However, these have a low water resistance, so that eliminates outdoor use. These disadvantages, the support plate according to the invention 1 not on, because their individual, plate-like layers 2 . 4 . 6 . 8th , ... are arranged relative to each other, that these biches are arranged offset with respect to their directions with different linear expansions to each other. For example, in 1 the layer 2 arranged so that their preferred (greater) longitudinal extent due to high humidity in the environment in the x-direction is greater than in the y-direction. When using fibrous materials as filler material are often the fibers 10 by the manufacturing process also preferably in the x-direction (here processing direction) oriented. The underlying layer 4 is then placed offset by 90 °, so that their greater length extension in the y-direction. The next, underlying layer 6 will turn in the same orientation as the plate 2 arranged. This stratification with different expansion orientation is then repeated according to the specifications of the manufacturer. As a result of this offset of the regions with preferred longitudinal expansion, the inhomogeneous expansion behavior of individual layers described at the outset can be largely compensated so that such layered WPC support plates have no or only an acceptable distortion even under unfavorable environmental conditions. Such plates can thus be used in the outdoor area with exceptionally high dimensional stability and water resistance.

The extent of the individual layers 2 . 4 . 6 . 8th can take place, for example, by the influence of temperature, by moisture or the like. The preferred direction of elongation is, as explained, in particular determined by the type of production and / or the fiber content and therefore can be analyzed in a relatively simple manner beforehand.

It is therefore important in the manufacturing process to provide the materials in such a way that the individual layers are actually aligned with the material 1 explained offset are joined together. The individual layers may be provided as roll material or as sheet material. According to the embodiment 1 the offset is about 90 °. Of course, other offset angles, such as 45 ° or the like can be used. For example, it is possible to orient a layer in the x-direction. To shift the next layer in its orientation by 45 ° and then to arrange the underlying layer in the y-direction, etc ..

2 shows a support plate 1 in the joined state. This joining can be done for example in a pressing station. The connection of the individual thin, plate-shaped WPC layers 2 . 4 . 6 . 8th This is preferably done by gluing, wherein a glue layer, for example a PUR layer 12 . 14 . 16 in a Beleimungsstation surface on the respective layer 2 . 4 . 6 . 8th is applied so that they are "locked" against each other. The layer thickness d of the WPC layers is preferably more than 1 mm, preferably in the range of 2 to 4 mm.

Depending on the application, other layers of wood or other suitable materials, such as glass fiber mats or the like can be interposed. In the concrete embodiment according to 2 is a large area with a fleece 18 Mistake. Such a nonwoven fabric may be made of fiberglass, textile and / or plastic material and may on the one hand act as a stabilizing layer and / or on the other hand facilitate the connection to a substrate, for example a floor.

The upper side is a decorative layer 20 provided, which forms a visual or wear layer. This decorative layer 20 may be carried out in the latter case with a wear layer.

By the crosswise blocking of the individual WPC layers 2 . 4 . 6 . 8th a very dimensionally stable plate is provided, which is particularly applicable in the outdoor area.

Through the manufacturing process, the WPC layers can be performed with a density gradient. For example, the wear-layer-side WPC layer may be formed in the higher density region adjacent to the decor / wear layer than in the underlying regions. The densities or materials of the individual WPC layers can also be chosen differently in order to form certain material properties.

As mentioned, suitable reinforcements, for example of a fiberglass or carbon fiber material may be provided to increase the bending stiffness.

Depending on the application, veneer layers made of wood or the like may also be provided in the area between WPC layers. Such a veneer layer can also form part of the decorative layer.

Thus, such panels can replace the conventional HDF / MDF or plywood panels so that high quality patio tiles, facade panels, waterproof parquet floors, control panels, etc. can be produced. The decorative layer 20 may then for example consist of a natural fiber material of high density, as used for example in the Celenio ^® floor of the applicant.

Disclosed is a support plate having a plurality of WPC layers that are offset from each other with respect to a preferred direction of expansion.

LIST OF REFERENCE NUMBERS

1

 support plate

2

 WPC layer

4

 WPC layer

6

 WPC layer

8th

 WPC layer

10

 fiber

12

 layer of glue

14

 layer of glue

16

 layer of glue

18

 fleece

20

 decorative layer

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• DE 202007018998 U1 [0004]
• WO 2010/145766 A1 [0004]
• WO 2011/006918 A1 [0028]

Claims (16)

Supporting plate for sheet-like components, which is designed to be provided with a decorative layer or a wear layer, with a layer structure, wherein a plurality of layers ( 2 . 4 . 6 . 8th consisting of a WPC material, which in turn consists of a filler material mixed with plastic base material, wherein the layers ( 2 . 4 . 6 . 8th ) have a different expansion behavior in a longitudinal and transverse direction of the plates and adjacent layers ( 2 . 4 . 6 . 8th ) are offset with respect to each other with respect to this longitudinal or transverse direction. A support plate according to claim 1, wherein the offset is about 90 °. Supporting plate according to one of the preceding claims, wherein the filling material is a fiber material, wherein adjacent layers are arranged in the preferred fiber orientation offset from each other. Supporting plate according to one of the preceding claims, wherein the inhomogeneous expansion behavior is predetermined by a machining direction in the manufacture of the layers, wherein the individual layers are then arranged offset with respect to each other with respect to this processing direction. Supporting plate according to one of the preceding claims, wherein the individual WPC layers are designed with a density gradient. Supporting plate according to one of the preceding claims, wherein this with a decorative layer ( 20 ) is executed. Supporting plate according to claim 6, wherein the decorative layer has a wear layer and optionally a clearcoat. Supporting plate according to claim 6 or 7, wherein the decorative layer contains a wood veneer.  Supporting plate according to one of the preceding claims, wherein at least one additional layer is formed as a veneer layer. Supporting plate according to one of the preceding claims, wherein at least one layer consists of a fiber-reinforced material, for example of glass fiber or carbon fiber mats. Supporting plate according to one of the preceding claims, wherein the layer structure contains further layers of other materials, for example a heavy foil, a stabilizing layer or the like. Supporting plate according to one of the preceding claims, wherein on the support side a nonwoven fabric is applied. Supporting plate according to one of the preceding claims, wherein it is provided for a sports floor, for furniture, for floor tiles, for floor panels or for wall, ceiling panels. Supporting plate according to one of the preceding claims, comprising a glue layer ( 12 . 14 . 16 ), which is applied flat on one of the WPC layers and preferably consists of a PUR material or a substitute. A support plate according to any one of claims 1 to 14, wherein the layers are joined by welding, gluing.  Supporting plate according to one of the preceding claims, wherein the layer thickness (d) is more than 1 mm, preferably between 2 and 4 mm.

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