DE102013113478A1 - Floor, wall or ceiling panel and method of making the same - Google Patents

Abstract

The invention relates to a floor, wall or ceiling panel and a method for its production. The panel 1 has a carrier plate 3 and an upper-side wear layer 4. The support plate 3 consists of a composite material of fibers and a hydraulic binder and the wear layer 4 consists of a natural material reinforced plastic. In particular, the carrier plate 3 is a fiber cement plate or a magnesite plate. The support plate 3 and the wear layer 4 are hot pressed together.

Description

The invention relates to a floor, wall or ceiling panel, which has a support plate and a top-side wear layer and a method for producing such a floor, wall or ceiling panel.

From the DE 10 2005 023 661 A1 is a decorative laminate or a floor panel known. The floor panel includes an upper decorative and abrasion resistant layer, an intermediate damping layer and a supporting core. The side edges of the floor panel are profiled and provided with connecting means. The cushioning intermediate layer comprises an elastic material, wherein the resilient material is bonded to the top of the supporting core. The upper decorative and abrasion resistant layer is bonded to this elastic material and comprises at least one decorative paper layer, at least one overlay paper layer, and optionally one or more base paper layers, wherein at least one of the paper layers is impregnated with a thermosetting resin.

The supporting core is made of materials such as a solid wood panel, a chipboard, a fiberboard, a polymer-based panel such as polyurethane or a fiber cement panel. The intermediate damping layer and the decorative and abrasion resistant layer is bonded to the supporting core by means of adhesive, heat and pressure. The adhesive is selected from melamine-formaldehyde, urea-formaldehyde, phenol-formaldehyde, hot-melt adhesive or combinations thereof.

The invention is based on the prior art, the task of creating a floor, wall or Deckenpaneel which is high-quality and durable at low cost manufacturing and has a great design freedom in the appearance of the wear layer and a method for producing such a floor -, wall or ceiling panel show.

The objective part of the object is achieved by a floor, wall or ceiling panel according to claim 1.

The solution of the procedural part of the task is set forth in claim 14.

Advantageous embodiments, developments and aspects of the invention are the subject of the dependent claims 2 to 13 or 15 to 21.

A floor, wall or ceiling panels has a carrier plate and a top-side wear layer. The carrier plate is a plate material made of a composite of fibers and a hydraulic binder. The wear layer consists of a natural material-reinforced plastic.

A fiber is a thin and flexible structure in relation to its length. Fibers may in the present case be natural fibers or chemical fibers. Natural fibers may be organic (vegetable or animal) or inorganic (mineral). Natural fibers are all textile fibers and fiber materials that are obtained without chemical modification from plant and animal material. Man-made fibers ("synthetic fibers") are produced synthetically. In the present case, preference is given to the use of an output carrier plate based on wood fibers, cellulose fibers and / or glass fibers. Also possible are basalt fibers, carbon fibers or aramid fibers.

Hydraulic binders are binders that set in the air as well as in the presence of water and are insoluble in water. These are z. B pozzolans, cement as well as trass or hydraulic limestones.

The carrier plate or the large-area output carrier plate used for the production of panels according to the invention may consist of fiber cement. Fiber cement is a durable composite of cement and tensile fibers.

Magnesite plates can also be used as carrier plate or output carrier plate. Magnesite plates consist of a mixture of magnesium oxide, calcium carbonate, silicates and fibers, in particular wood and / or glass fibers. One advantage of magnesite sheets is their low weight and low thermal conductivity, as well as their fire resistance. Magnesite plates are classified as non-combustible.

So that the panels produced from the output carrier plate or the carrier plate of the panel later have the necessary properties in the composite, the carrier plate or output carrier plate must have a transverse tensile strength of greater than or equal to (≥) 1.4 N / mm ² . Preferably, the transverse tensile strength is greater than or equal to (≥) 1.8 N / mm ² .

The wear layer consists of a natural material-reinforced plastic. In particular, wood fibers or wood flour or powder can be used as natural material. In addition to wood, materials such as jute or flax can be used, as well as bamboo, nettle or hemp. The use of cork powder or cork granules is also possible.

Preferably, the wear layer of a fibrous and / or powdered natural material and a thermosetting plastic binder and also contains pigments, in particular color pigments and corundum. The binder is in particular a melamine binder.

A useful layer considered to be particularly advantageous in practice is formed from a natural mixture of wood fibers or wood powders, pigments (insoluble coloring substances), cork and melamine (plastic) binder and corundum. Corundum improves in particular the abrasion properties. In addition, the wear layer is also impact and non-slip. The entire panel is flame retardant.

The carrier plate and the wear layer are pressed together, in particular hot pressed. An adhesion promoter may be provided between the carrier plate and the wear layer. The adhesion promoter improves the adhesion between the wear layer and the carrier plate. Preferably, an adhesion promoter is applied separately as part of a surface pretreatment of the carrier plate or the output carrier plate. Suitable adhesion promoters are modified polyolefins or even silane coupling agents. Furthermore, one-component polyurethane precursors or primers are suitable. A bonding agent which is advantageous for practical use is a PUR binder which cures with moisture absorption from the ambient air or the starting carrier plate.

On the underside of the support plate a Gegenzuglage is provided. The Gegenzuglage supports the dimensional stability of the panels and serves for moisture barrier and impact sound insulation. The counteracting layer can be identical in material technology with the material of the wear layer.

The surface of the wear layer may be ground, embossed, brushed and / or sealed. Furthermore, the surface of the wear layer may be printed with a decor. It is also possible that the surface of the wear layer has a structure. An optical effect can be achieved in this case if the surface structure and a decorative pressure are synchronous. The surface structure is preferably produced during the pressing process. Here, the surface of the wear layer is replaced by a structural sheet or a structure donor a structure, a pattern or ornaments. The structure may vary in the degree of gloss in partial areas. Furthermore, different structure depths are possible.

The inventive method for producing floor, wall or ceiling panels according to the invention is characterized by the following

• – Bildung eines Mehrschichtkörpers, wozu
• – eine großflächige Ausgangsträgerplatte aus einem Verbundwerkstoff aus Fasern und einem hydraulischen Bindemittel bereitgestellt wird und
• – auf die Oberseite der Ausgangsträgerplatte zumindest eine Lage eines Gemischs aus Naturwerkstoffpartikeln und Kunststoffpartikeln aufgebracht wird sowie
• – unterseitig der Ausgangsträgerplatte eine Gegenzuglage angeordnet wird;
• – Verpressen des Mehrschichtkörpers in einer Presse unter Temperatureinfluss, wobei die Nutzschicht durch Plastifikation und Härtung des Gemischs aus Naturwerkstoffpartikeln und Kunststoffpartikeln gebildet und mit der Ausgangsträgerplatte verbunden wird sowie die Gegenzuglage mit der Unterseite der Ausgangsträgerplatte verbunden wird;
• – anschließend der verpresste Mehrschichtkörper aus der Presse entnommen und in einzelne Paneele getrennt wird und
• – die Paneele an ihren Seitenrändern profiliert und mit Verbindungsmitteln versehen werden.
• Der Pressvorgang bei dem die Lagen des Mehrschichtkörpers miteinander verpresst und verbunden werden, wird mit folgenden Prozessparametern durchgeführt:
• – der Pressdruck ist größer oder gleich (≥) 1.000 Kilopascal (kPa), vorzugsweise größer oder gleich (≥) 3.500 Kilopascal (kPa),
• – die Presstemperatur ist größer oder gleich (≥) 100 °C, insbesondere größer oder gleich (≥) 120 °C, und liegt vorzugsweise im Temperaturbereich zwischen 180°C und 210 °C,
• – die Presszeit beträgt kleiner oder gleich (≤) 120 Sekunden und liegt insbesondere zwischen 10 und 60 Sekunden.

Steps:

• - Forming a multi-layer body, including
• - Providing a large-scale output carrier plate made of a composite material of fibers and a hydraulic binder, and
• - At least one layer of a mixture of natural material particles and plastic particles is applied to the top of the output carrier plate and
• - A Gegenzuglage is arranged on the underside of the output carrier plate;
• - Pressing the multi-layer body in a press under the influence of temperature, wherein the wear layer is formed by plasticization and curing of the mixture of natural material particles and plastic particles and connected to the output carrier plate and the Gegenzuglage is connected to the underside of the output carrier plate;
• - Then the compressed multilayer body is removed from the press and separated into individual panels and
• - The panels are profiled at their side edges and provided with connecting means.
• The pressing process in which the layers of the multilayer body are pressed together and joined is carried out with the following process parameters:
• The pressing pressure is greater than or equal to (≥) 1,000 kilopascals (kPa), preferably greater than or equal to (≥) 3,500 kilopascals (kPa),
• The pressing temperature is greater than or equal to (≥) 100 ° C, in particular greater than or equal to (≥) 120 ° C, and is preferably in the temperature range between 180 ° C and 210 ° C,
• - The pressing time is less than or equal to (≤) 120 seconds and is in particular between 10 and 60 seconds.

The pressure is often given in practice in kg / cm ² . Rounding up, it can be said that 1,000 kPa corresponds to 10 kg / cm ² and 3,500 kPa corresponds to 35 kg / cm ² .

Starting product in the manufacture of floor, wall or ceiling panels according to the invention is a large-area carrier plate, referred to herein as the output carrier plate. A large-area output carrier plate means that it has a size in length and width, which corresponds to a multiple, in particular an integer multiple, the width of a single panel. Such a large-sized output carrier plate is rectangular in configuration and has a size of 2,000 mm to 5,600 mm in length and 1,200 mm to 2,100 mm in width. Usually, the output carrier plate has a thickness of 5 mm to 12 mm.

The output carrier plate may be ground prior to processing, preferably with a sandpaper grain in the range between 80 to 180 grit. On the top of the base plate output can be applied as part of a surface preparation a bonding agent. The adhesion promoter improves the adhesive strength between the wear layer to be produced and the output carrier plate.

The mixture of natural material particles and plastic particles is preferably provided in free-flowing state, for example as granular matter in granular or pulverulent form. For application to the output carrier plate, the mixture is spread uniformly on top of the output carrier plate.

The layer of the mixture applied to the output carrier plate can be preconditioned. For this purpose, prior to pressing, a semifinished product layer is formed from the mixture, for example by heat application and / or moisture supply. The mixture reacts to form a film adhered to the surface of the output carrier plate and having a gel or waxy structure.

This semi-finished layer can be printed before the compression of the multilayer body. Printing is preferably effected by means of digital printing and a system of printing inks adapted to the resin of the wear layer.

When the multilayer body is pressed in a press, the plastic particles within the mixture of natural material particles and plastic particles are plasticized. The plastic particles go from solid to a deformable flowable state. They become plastically deformable and cure under pressure and temperature. The natural material particles are integrated in the plastic matrix. The mixture is adjusted so that water can escape or evaporate during pressing. In addition, the natural material particles can absorb moisture from the condensation process.

The plastic particles are made of resin. This is in particular a thermosetting synthetic resin. Colored or transparent melamine resins or melamine / polyurethane resin mixtures can be used. One aspect of the invention aims to use resins that cure under heat and pressure. In this context, the use of aminoplastic, thermosetting resins, such as melamine resins or polyurethane (PUR) -modified resins or thermoplastic polyurethane offers.

A multilayer body is formed, comprising the output carrier plate and the applied layer of the mixture of natural material particles and plastic particles. This mixture can furthermore contain pigments, in particular color pigments and / or corundum. On the underside of the output carrier plate a Gegenzuglage is arranged. The multilayer body thus formed is then pressed in a press. When hot-pressing, the wear layer is formed from the layer or layers of the mixture and inextricably bonded to the output carrier plate. Further, the Gegenzuglage is permanently connected to the bottom of the output carrier plate. The pressing of the multilayer body takes place in a press and that at a pressing pressure of greater than or equal to (≥) 1,000 kilopascals (kPa). Preferably, the pressing pressure is above 3,500 kilopascals (kPa). The press used is in particular a short-cycle press or a continuous press. The pressing temperature is greater than or equal to (≥) 120 ° C. Preferably, the pressing temperature is between 180 ° C and 210 ° C. The pressing temperature refers to the temperature at the press plate of the press. In the context of the method according to the invention, the pressing time at which the multilayer body is subjected to pressure in the press is less than 120 seconds, in particular between 10 seconds and 60 seconds.

During the pressing process, the surface of the wear layer can be given a structure, a pattern or ornaments by means of a structured sheet metal or a structured donor. The structure may vary in the degree of gloss in partial areas. Furthermore, different structure depths are possible.

The counteracting position compensates for stresses in the multilayer body. The counter-tension layer may be a veneer, a paper, a film or else a film, in particular a synthetic resin film. Appropriately, a Gegenzugfurnier or a Gegenzugpapier is resined or impregnated with synthetic resin. The counter-tension layer is pressed in the manufacture of the floor, wall or ceiling panel according to the invention together with the output carrier plate, the veneer and the resin layer and connected to the bottom side with the output carrier plate.

One aspect of the invention provides for a similar construction of the counteracting layer as the wearing layer. The Gegenzuglage is then also made of a mixture of natural material particles and plastic particles and indeed during hot pressing of the multilayer body in the press. This aspect also makes it possible for the counter-tension layer to also form the wear layer. As a result, a turning panel is created in the Optionally one of the flat sides can be laid upwards as a visible wear layer.

After the pressing process, the pressed multi-layer body is divided into individual panels. The individual panels are profiled in a subsequent step on their side edges. The profiling takes place after cooling of the compressed multilayer body to room temperature. The profiling is used in particular for the formation of connecting means on the longitudinal and narrow sides of the panels.

The panels are profiled on their side edges and provided with connecting means. Connecting means may be configured as a groove and springs. Preferably, the side edges are provided with a click connection. Furthermore, the panels may be circumferentially provided with a chamfer at their upper edges.

One aspect continues to be to form circumferentially at the edge of the wear layer a bevel as a decorative optically delimiting edge. Furthermore, the surface of the wear layer can be printed with a decor. Preferably, the printing is done by means of digital printing. In this case, a system of printing inks adapted to the resins used is used. It is possible to apply a seal on the wear layer. As a seal, the order of a color, a stain, an oil or a paint or paint systems understood.

It is particularly advantageous that the panel or the surface of the wear layer can be subjected to a mechanical surface treatment after pressing. As part of a surface treatment in particular grinding or brushing of the surface takes place. This can accentuate the natural look of the surface. By an irregular surface treatment, an aged structure or optics can be achieved a so-called vintage look. The surface of the panel may thus have, for example, a saw-rough surface or chatter marks or grinding errors or the like.

As already mentioned, the wear layer is formed from the mixture of natural material particles and plastic particles applied to the upper side of the output carrier plate. The mixture may have further constituents such as effect materials or color pigments and corundum or also fillers in the form of organic and inorganic materials, for example mica.

One aspect of the invention aims at the fact that the wear layer is formed from two or more mixed layers. The individual layers may be different in their composition, as well as in terms of color design, from each other. This allows the production of special effects in the wear layer, for example, in which two different colored layers are pressed together. For example, a net-like structured surface can also be produced.

An inventive floor, wall or ceiling panel is inexpensive to manufacture and high quality. The panels impress with their appearance and their mechanical properties. A particular advantage of the invention is the great design freedom in the appearance of the wear layer. Depending on the composition of the mixture from which the wear layer is formed, a wide variety of color and haptic designs of the panels can be produced.

The invention is described below with reference to drawings. Show it:

1 in an enlarged view a cross section through the region of the longitudinal side of a first embodiment of a floor panels and

2 in an enlarged view a cross section through the region of the longitudinal side of a second embodiment of a floor panels.

An inventive floor panel is in the 1 With 1 and in the 2 With 2 designated. The 1 and 2 are technically schematized and not to scale.

The floor panel 1 . 2 is usually configured rectangular and has a support plate 3 with a top-side wear layer 4 on. Lower side of the carrier plate 3 is a return 5 provided with the bottom 6 the carrier plate 3 glued over the entire surface. The return 5 supports the dimensional stability of the floor panel and serves as moisture barrier as well as for impact sound insulation.

The carrier plate 3 consists of a composite of fibers and a hydraulic binder. In particular, the carrier plate 3 made of fiber cement or the carrier plate 3 is a magnesite plate. The wear layer 4 consists of natural material-reinforced plastic. In particular, the wear layer is formed from a fibrous and / or powdered natural material and a duroplastic plastic binder. Furthermore, the wear layer contains 4 Pigments, in particular color pigments and corundum. The natural material is chosen so that the wear layer 4 is open to diffusion. When hot pressing of wear layer 4 and support plate 3 is the material of the wear layer 4 water vapor permeable.

The floor panel 1 . 2 indicates at its margins 7 respectively. 8th Connecting means in the form of a groove 9 and spring 10 on. These are configurationally coordinated. You realize that the spring 10 and the groove 9 in or on the support plate 3 are provided. In the grooves 9 and on the springs 10 are coupling agents 11 formed, which in adjacent in a floor covering floor panels 1 . 2 engage each other in latching engagement. The coupling agent 11 include the grooves 9 upstream limited resilient locking tongues 12 with locking grooves 13 below the springs 10 can be joined. About the springs 10 and the grooves 9 can the floor panels 1 . 2 gap-free and glueless tensile and pressure resistant be added over their long sides as well as on their head sides.

For the production of a floor panel 1 . 2 a multilayer body is formed. For this purpose, a large-area output carrier plate made of a composite material of fibers and a hydraulic binder is provided. At least one layer of a mixture of natural material particles and plastic particles is applied to the upper side of the output carrier plate. The mixture is free-flowing and has a granular or powdery structure. On the underside of the output carrier plate a Gegenzuglage is arranged. Subsequently, the multilayer body is hot pressed in a press and firmly connected to the output carrier plate. Likewise, the Gegenzuglage 5 firmly connected to the output carrier plate. When hot pressing is the wear layer 4 formed by plasticization and curing of the mixture of natural material particles and plastic particles.

During pressing, the pressing pressure is more than 1,000 kilopascals (kPa). Preferably, the pressing pressure is greater than or equal to 3,500 kilopascals (kPa). The pressing temperature is above 100 ° C, in particular, the pressing temperature is greater than or equal to 120 ° C. Preferably, the pressing temperature is between 180 ° C and 210 ° C. The pressing time is less than 2 minutes (120 seconds). In particular, the pressing time is between 10 and 60 seconds.

The compressed multilayer body is removed from the press and after cooling into individual panels 1 . 2 separated. In a further processing step, the panels 1 . 2 at their margins 7 . 8th profiled and with the connecting means 9 . 10 Mistake.

At the floor panel 1 , like in the 1 shown, is the wear layer 4 from one location 14 a mixture of natural material particles and plastic particles formed. At the floor panel 2 , like in the 2 to recognize, is the wear layer 4 from two layers 15 . 16 formed from different mixtures of natural material particles and plastic particles. When pressing is the surface 17 the wear layer 4 embossed and provided with a structure. Here are the two layers 15 . 16 partially pressed together.

As part of a surface pretreatment, the surface of the output carrier plate can be provided with a bonding agent. This can be done on both sides, ie on the wear layer 4 page as well as on the opposite 5 facing side of the output carrier plate.

Generally, the surface can be 17 the wear layer 4 sanded, embossed, brushed and / or sealed. Furthermore, the surface can be 17 the wear layer 4 be printed with a printed decor.

LIST OF REFERENCE NUMBERS

1

 floor panel

2

floor panel

3

support plate

4

wear layer

5

return

6

bottom

7

margin

8th

margin

9

groove

10

 feather

11

 coupling means

12

 locking tongues

13

 locking grooves

14

 location

15

 location

16

 location

17

Surface of 4

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 102005023661 A1 [0002]

Claims (21)

Floor, wall or ceiling panel ( 1 . 2 ), which is a carrier plate 3 and a top-side wear layer ( 4 ), characterized in that the carrier plate ( 3 ) consists of a composite material of fibers and a hydraulic binder and the wear layer ( 4 ) consists of a natural material reinforced plastic. Floor, wall or ceiling panel according to claim 1, characterized in that the support plate ( 3 ) consists of fiber cement. Floor, wall or ceiling panel according to claim 1, characterized in that the support plate ( 3 ) is a magnesite plate. Floor, wall or ceiling panel according to at least one of claims 1 to 3, characterized in that the support plate ( 3 ) and the wear layer ( 4 ) are pressed together. Floor, wall or ceiling panel according to at least one of claims 1 to 4, characterized in that between the support plate ( 3 ) and the wear layer ( 4 ) An adhesion promoter is provided. Floor, wall or ceiling panel according to at least one of claims 1 to 5, characterized in that on the underside of the support plate ( 3 ) a counter-position ( 5 ) is provided. Floor, wall or ceiling panel according to at least one of claims 1 to 6, characterized in that the wear layer ( 4 ) consists of a fibrous and / or powdered natural material and a thermosetting plastic binder and also contains pigments and corundum. Floor, wall or ceiling panel according to at least one of claims 1 to 7, characterized in that the wear layer ( 4 ) is open to diffusion. Floor, wall or ceiling panel according to at least one of claims 1 to 8, characterized in that the surface ( 17 ) of the wear layer ( 4 ) is ground, embossed, brushed and / or sealed. Floor, wall or ceiling panel according to at least one of claims 1 to 9, characterized in that the surface ( 17 ) of the wear layer ( 4 ) is printed with a decor. Floor, wall or ceiling panel according to at least one of claims 1 to 10, characterized in that the surface ( 17 ) of the wear layer ( 4 ) has a structure. Floor, wall or ceiling panel according to claim 10 and 11, characterized in that the surface structure and a decor pressure run synchronously. Floor, wall or ceiling panel according to at least one of claims 1 to 12, characterized in that the surface ( 17 ) of the wear layer ( 4 ) has two or more different degrees of gloss. Method for producing a floor, wall or ceiling panel, which comprises a support plate ( 3 ) and a top-side wear layer ( 4 ), characterized by the following steps: - forming a multi-layer body, for which - a large-area output carrier plate made of a composite material of fibers and a hydraulic binder is provided and - at least one layer of a mixture of natural material particles and plastic particles is applied to the top of the output carrier plate and - underside the output carrier plate a Gegenzuglage ( 5 ) is arranged; - Pressing of the multilayer body in a press under the influence of temperature, wherein the wear layer ( 4 ) is formed by plastification and curing of the mixture of natural material particles and plastic particles and connected to the output carrier plate and the counter-tension layer ( 5 ) is connected to the underside of the output carrier plate; - Then the compressed multilayer body removed from the press and into individual panels ( 1 . 2 ) and - the panels ( 1 . 2 ) at their margins ( 7 . 8th ) profiled and with connecting means ( 9 . 10 ). A method according to claim 14, characterized in that during pressing of the multilayer body - the pressing pressure is greater than or equal to (≥) 1,000 kilopascals (kPa), preferably greater than or equal to (≥) 3,500 kilopascals (kPa), - the pressing temperature is greater than or equal to ( ≥) 100 ° C, in particular greater than or equal to (≥) 120 ° C, is preferably between 180 ° C and 210 ° C and - the pressing time is less than or equal to (≤) 120 seconds, in particular between 10 and 60 seconds , A method according to claim 14 or 15, characterized in that the mixture of natural material particles and plastic particles furthermore pigments, in particular color pigments, and minerals, in particular corundum, are added. Method according to at least one of claims 14 to 16, characterized in that a bonding agent is applied to the upper side of the starting carrier plate before the application of the mixture, or an output carrier plate is provided on the upper side provided with an adhesion promoter. Method according to at least one of claims 14 to 17, characterized in that the position of the mixture of natural material particles and plastic particles preconditioned before the pressing of the multilayer body and a semi-finished layer is formed. A method according to claim 18, characterized in that the semifinished layer is printed before the pressing of the multilayer body. Method according to at least one of claims 14 to 19, characterized in that during the pressing of the multilayer body a structure in the surfaces ( 17 ) of the wear layer ( 4 ) is pressed. Method according to at least one of claims 14 to 20, characterized in that the wear layer ( 4 ) is formed from two or more mixed layers, in particular from two or more layers of different color different mixtures.

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