DE102014012188A1 - Plate for a floor, wall or ceiling covering or for a furniture component and method and pressing device for producing such a plate - Google Patents

Abstract

The invention relates in particular to a plate (1) for a floor, wall or ceiling covering or for a furniture component, preferably flooring, wall covering or ceiling panel or furniture component plate, with a flat support plate (2) and one on the support plate (2) applied upper layer (3). According to the invention it is provided that the carrier plate (2) is made of a consolidated nonwoven fabric or that the carrier plate (2) has at least one layer of a consolidated nonwoven fabric.

Description

The invention relates to a plate for a floor, wall or ceiling covering or for a furniture component, preferably flooring, wall covering or ceiling panel or furniture component plate, with a flat support plate and an applied to the support plate upper layer.

Plates of the aforementioned type, which are also referred to as panels or planks, as far as the area floor, wall or ceiling is concerned, have long been known in practice. Plates of the aforementioned type for the area floor, wall or ceiling are usually provided on the edge side with a tongue and groove connection in order to be able to be laid securely on the ground to a corresponding surface. Such compounds are also referred to in practice as a bung or bung. As a rule, so-called click connections are used as connection technology of the plates. Plates with click-connections, which are usually connected to each other via a Einschwenkbewegung and locked together in the clicked state, for example, from DE 297 24 428 U1 known. In the known plates, the support plate is usually made of MDF, HDF, plastic or a ground, assembled with binder wood fiber.

Carrier panels for laminates made of MDF or HDF are usually about 82% spruce or pine with a share of sawed wood and about 11% urea resin, 5 to 7% water and 1% paraffin wax. The carrier plates are manufactured, transported, separated and profiled at great expense. The resulting chips are usually utilized thermally. A disadvantage of the known laminates or plates used for it is that the plate production is relatively complex overall and that for the production of HDF / MDF, a relatively high proportion of new wood is used.

Object of the present invention is therefore to provide a plate of the type mentioned above and a related method available, making it possible to produce plates of the aforementioned type easier, cheaper and more environmentally sustainable.

The above object is achieved according to the invention in a plate of the type mentioned above essentially in that the carrier plate is made of a consolidated nonwoven fabric or at least one layer of a consolidated nonwoven fabric.

A non-woven fabric of the type according to the invention is understood to mean a structure of limited-length fibers, continuous filaments, also referred to as filaments, or cut fibers of any kind and origin, which have in some way been joined or bonded together to form a nonwoven fabric. The length of the fibers in natural fibers is generally 30 to 90 mm, in the case of synthetic fibers the length is generally between 50 and 70 mm.

Nonwovens are usually flexible textile fabrics made of fibers that have a comparatively small thickness compared to their length and width.

In the context of the present invention, it has surprisingly been found that a consolidated, needled nonwoven fabric can easily meet the requirements usually imposed on a support plate, such as strength and stability. In addition, the use of a consolidated nonwoven fabric as a material of the support plate offers further significant advantages.

First of all, a nonwoven material is an alternative to wood or wood materials as a material of the support plate material that is very cost-effective and ecologically sustainable. In addition, the solidified nonwoven fabric provides very good acoustics and sound insulation properties, which can only be achieved when using a carrier plate made of a wood material, if in addition a soundproofing mat is provided in the laminate in question. In addition, the degree of solidification of the nonwoven fabric can produce a different ride for the user. A less strongly consolidated nonwoven fabric results in a softer ride, while a strongly consolidated nonwoven fabric results in a similarly hard ride as when using a wooden backing plate.

Furthermore, it has been shown that the processing and processing of the nonwoven carrier plate is much easier possible than in a carrier plate made of a wood material. First of all, much deeper structures can be achieved by compressing the nonwoven as a carrier plate in combination with resinated papers as a decorative layer if the surface structure is pressed directly during the pressing process of the carrier plate. In addition, it is in principle possible to pre-form or profile the groove-tongue or click geometry at the edge on the plate, so that the profiling effort and the associated costs can be reduced. Finally, a support plate made of a consolidated nonwoven material with respect to a support plate made of a wood material has improved thermal insulation properties in a Support plate can be realized from a wood material only by a supplementary thermal barrier coating.

The abovementioned advantages arise at least partially even when the carrier plate has at least one layer of a consolidated non-woven fabric. In this alternative, the carrier layer may not be complete, but only partially made of a consolidated nonwoven fabric. For example, a layer of a consolidated nonwoven fabric and a layer of HDF or MDF may be provided. Also, a sandwich construction with an inner HDF or MDF layer and outer consolidated nonwoven fiber layers is possible in the same way as an internally solidified fiber fleece layer and outer HDF or MDF layers.

In principle, the non-woven fabric used for the carrier plate according to the invention can be made of any fibers that are commonly used for non-woven production. Thus, in principle, vegetable, animal, mineral and / or recycled fibers and fibers of natural and / or synthetic polymers in question. It is understood that mixtures of the aforementioned fibers in any combination are possible. If synthetic fibers are used, they consist predominantly of PP and / or PET.

In a preferred embodiment of the present invention, which is particularly based on an ecological sustainability and thus takes into account that in the carrier plate production a considerable amount of waste is obtained, which should preferably be well usable, it is provided that the nonwoven fabric at least predominantly from vegetable fibers, especially from sustainable produced flax, kenaf and / or hemp fibers should exist.

For solidification of the nonwoven fabric according to the invention, basically all known solidification methods can be used, which are also used in nonwoven production from a fiber raw material. The methods of mechanical, chemical or thermal solidification can each be used alone or in combination.

In the case of mechanical consolidation, the composite of the fibers is produced by frictional engagement or by a combination of frictional and positive locking. In the frictional connection, the distance of the adjacent fibers in the nonwoven base material is reduced by nonwoven compaction. This increases the adhesion of the fibers to each other and allows higher forces to be transmitted. The resistance of the non-woven fabric to deformation becomes higher while being stronger. Compression can be achieved, for example, by shrinkage of all fibers or a proportion when the fibers are shrinkable on exposure to heat. Likewise, the compaction can be carried out by pressing, for example by means of calendering or by walking, in which the fibers of the nonwoven fabric according to the invention must be feltable and by simultaneous thermal, chemical and mechanical effects entangled with each other.

In the nonwovens made by combining friction and form-fitting binding, the fibers of the nonwoven fabric according to the invention are entangled with one another by mechanical effects. This can be done, for example, by needling by a variety of special, arranged in a needle bed or beam needles and is punched out.

In the chemical solidification process, the composite of the fibers is achieved by material adhesion by means of additives. The bonding of fibers by means of additives, commonly referred to as binders, is also referred to as adhesive bonding. In the vast majority of chemical processes, the binder is applied in liquid form (eg polymer dispersions) to or in the nonwoven fabric and cured by subsequent heat treatment (drying, condensation, polymerization), whereby the nonwoven is solidified. The application of the liquid binder can be done for example by impregnation or spraying. Typical binders may be, for example, acrylate resins, epoxy resins and / or melamine resins.

In the case of thermal consolidation, the composite of the fibers is likewise produced by material bonding, although a distinction is made between adhesive and cohesive composite. Prerequisite for the thermal consolidation are additional thermoplastic components, in particular in the form of thermoplastic fibers.

In connection with the present invention, it has further been found that very good solidification properties are achieved when the nonwoven fabric is impregnated with binder, ie impregnated, and / or thermoplastic polymer fibers are contained in the nonwoven fabric.

In experiments in the context of the present invention, it has been found that very good properties of the consolidated from the consolidated nonwoven backing plate are achieved when the support plate has a greater proportion of solidified nonwoven material and a smaller proportion of binder and / or thermoplastic polymer fibers. Preferably, the proportion of binder or thermoplastic polymer fibers is at most 40 and in particular at at most 30% by weight. It is even possible to reduce the proportion of binder to 20 wt .-% or even less. In a particularly preferred embodiment of the invention, a mass ratio in the range of 75 wt .-% of nonwoven material and 25% of binder or thermoplastic polymer fibers has been used.

Incidentally, it has been found that the proportion of binders may vary depending on the type of the binder. The percentage of thermoplastic binders should be higher for the same plate density and stability than the required percentage of resins as a binder.

In connection with the present invention, it has furthermore been found that it is particularly preferred to use as the starting material of the nonwoven fabric according to the invention, if it is not yet in the solidified state according to the invention, a nonwoven fabric whose density is between 80 kg / m ³ and 300 kg / m ³ , preferably between 100 kg / m ³ and 210 kg / m ³ and in particular between 150 kg / m ³ and 170 kg / m ³ should be. In the solidified state according to the invention, the density of the nonwoven fabric should be between 350 kg / m ³ and 1000 kg / m ³ , in particular between 400 kg / m ³ and 900 kg / m ³ and particularly preferably between 750 and 850 kg / m ³ .

It should be pointed out in this context that it is basically possible to form the carrier plate in a multi-layered manner, wherein one layer of the carrier plate can have a greater density than the other layer. This will be discussed in more detail below.

In connection with the selection of the fibrous material according to the invention for the intended purpose for use as a carrier plate, it has proven to be particularly preferred that the degree of compaction of the unconsolidated fibrous web to the consolidated fibrous web is between 10: 1 and 2: 1, preferably between 8: 1 and 4: 1 and in particular between 5: 1 and 4: 1.

Furthermore, it has been found in connection with strength and stability studies that the support plate according to the invention should have a thickness between 4 and 15 mm, preferably between 6 and 12 mm when used as a floor, wall or ceiling covering. When used as a furniture panel, the thickness of the support plate is preferably between 5 and 30 mm.

Incidentally, the support plate according to the invention, when used in the area of floor, wall and ceiling, as has already been indicated at the outset, on the edge side a tongue and groove contour preferably in the form of a click connection.

In a particularly preferred embodiment of the invention, it is provided that the carrier plate is more strongly solidified in the region of the tongue and groove contour than outside the region of this contour. In this way, the locking profile can be made much more stable and the risk of damaging the groove and / or the spring is reduced.

The higher degree of solidification in the region of the connection contour can be realized in different ways. On the one hand, it is possible to use a multilayer support plate, as already explained, in which a strongly consolidated fibrous nonwoven layer is used in the region of the locking contour. The thickness of this sub-layer of the carrier layer is at least slightly greater than the maximum height of the groove of the locking contour, so that the groove can be completely formed within this more solidified carrier layer. Another alternative is to strengthen the nonwoven material in the area of the locking contour stronger. This area can already be more compacted in the production of the carrier plate in order to achieve a stronger solidification in this way.

It should be pointed out that the two alternatives mentioned above can also be used in combination with each other.

Incidentally, it has been determined according to the invention that further positive effects can be achieved by the multi-layered nature of the carrier plate. A multilayer carrier plate according to the invention is already present if the carrier plate has at least two layers which have a different degree of compaction and / or solidification. However, support plates with three, four, five or an even greater number of individual layers are also possible, wherein the individual layers can in principle all have different compaction and / or solidification degrees. However, at least two groups of layers are present, one group having a higher degree of solidification and compaction and / or the other group having a different degree in this respect.

Incidentally, it is understood that the different layers of the carrier plate can be made not only of one but also of different nonwoven materials.

In addition to achieving a special stability of the locking contour or alternatively can be selected by choosing different layers of Support plate also realize a different elastic behavior of the plate. If, for example, a layer with a less strongly consolidated nonwoven fabric is used in combination with a layer with a more strongly consolidated nonwoven fabric, this can create a feeling of being perceived as very pleasant by the user. In such an embodiment, as the upper layer of the carrier plate, a more strongly consolidated nonwoven fabric should be realized, while underneath a layer with a less strongly consolidated nonwoven fabric is used. For example, a support plate could be constructed in three layers, which has an upper relatively strongly consolidated layer, an underlying, less strongly solidified and thus more elastic layer and underneath a turn stronger consolidated layer within which the locking contour is formed. In this case, the individual layers, as stated above, consist of the same nonwoven material, wherein the stronger solidification is produced only due to different compaction, but it can also be different nonwoven materials are used, which fulfill the aforementioned effect and function.

As has already been stated, it may of course also be provided to provide an inner HDF or MDF layer, for example 3 mm thick, and above and below each a consolidated fibrous nonwoven layer. In this embodiment, the locking contour can then be provided in the central HDF or MDF layer.

Furthermore, it has been found in the context of the present invention that it is advantageous if the upper layer is also formed multilayer. Thus, the upper layer may be a printed, resinated or non-resinated paper layer, in particular a decorative paper layer, a protective overlay, in particular of corundum, an outer wear layer of plastic, in particular vinyl, PUR or PP, a printed plastic support, in particular of vinyl, a lacquer layer, in particular a Structure lacquer layer, and / or have a printed nonwoven layer. In this context, it is possible to apply a further layer of another or the same nonwoven material on the carrier layer on the top side already during needling of the nonwoven fabric to be used for carrier plate production. This creates a printable layer directly. It is understood that combinations of the aforementioned layers with one or more of the aforementioned alternatives are readily possible.

By realizing the upper layer in the above-mentioned manner, it is ultimately possible to produce a plate which, on the outside or in the installed state, can not be distinguished from a plate known from the prior art with a carrier plate consisting of a wooden material, but otherwise complementary has the aforementioned improved properties and offers advantages.

Furthermore, the plate according to the invention preferably has a lower layer, which is applied to the carrier layer on the underside. This lower layer can have different properties or ensure functions. On the one hand, the lower layer can serve as a counterweight or underlay in order to avoid any undesired distortion of the carrier plate according to the invention. In addition, can be achieved by a lower layer complementary sound insulation or acoustic properties, which go beyond the already resulting by realization of the invention advantageous sound insulation and acoustic properties. For example, a lower layer of cork may be provided. However, the bottom layer may also basically consist of a nonwoven material, which is not solidified in accordance with the invention, however. Incidentally, it is understood that the lower layer may also be multi-layered, if required for certain applications.

Moreover, the present invention relates to a method for producing a panel for a floor, wall or ceiling covering or for a furniture component, preferably a floor covering, wall covering or ceiling panel or a furniture board, wherein the plate is a flat support plate and one on the support plate having applied upper layer.

As has already been stated above, plate production in the prior art takes place in such a way that the carrier plates are produced from a wood material at considerable expense.

The invention now goes a different way, wherein for the production of the support plate, a consolidated, needled nonwoven fabric is produced. The advantages resulting from the use of the consolidated fibrous web for the carrier plate are expressly referred to.

In the invention, the above-described mechanical, chemical and / or thermal solidification of the nonwoven fabric in connection with the production of the carrier plate can be realized both by a continuous and by a discontinuous process. In this case, the continuous production preferably takes place on a rolling device in which the compaction can be carried out by at least one pair of rollers with a top and a bottom roller. It is understood that the rolling device following the first pair of rollers and a plurality of may have further rolls or further pairs of rolls. In the discontinuous production, the so-called Kurztaktverpressung offers, in which a lower and / or an upper pressing part are provided.

As a result of using either the continuous or the batch process to solidify the nonwoven fabric, a rectangular sheet having a defined edge length, width and height results. The height of the nonwoven fabric and the selected pressing pressure control the specific gravity of the plate.

Regardless of the manufacturing process, it is such that the solidification device, ie either the rolling device or the short-cycle press, performs the compaction or compaction of the nonwoven fabric in the manner according to the invention via corresponding pressure and / or corresponding temperatures. Accordingly, the respective pressing device is provided with corresponding pressing cylinders and / or heating devices.

In order to achieve a cost-effective production of the plate according to the invention, it makes sense to produce the plate from a base plate which is several times larger than the plate itself. The base plate is after its production, that is, after the solidification of the non-woven fabric according to the invention, divided into a plurality of individual plates. Accordingly, the size of the baseplate is approximately equal to a multiple of the dimensions of a single plate.

Incidentally, in connection with the method according to the invention, it has been found that it is possible to press the tongue and groove joint at least in regions with the aid of the pressing device. It is also possible that only a precontouring of the tongue and groove connection takes place in the pressing device. In this case, the tongue and groove connection can be realized from the outset when pressing the fiber fleece. In principle, however, it is also possible that already pre-pressed non-woven plates with or without locking contours are provided laterally with a corresponding (supplementary) locking contour by a further pressing operation (continuous in a continuous or discontinuous manner), the subsequently re-pressed area being substantially harder. The pre-contouring or, if necessary, subsequent pressing of the tongue and groove joint has the significant advantage that comparatively little material of the backing plate has to be milled away for the final contouring of the locking contour. This reduces the production costs in creating the locking contours considerably, which has a corresponding cost-effective.

It is understood that, of course, it is of course also possible to perform any contouring or Vorkonturierung when solidifying the fiber fleece, so produce a base plate in a continuous or discontinuous process that is profiled edge only after its final creation.

Incidentally, the method according to the invention has the advantage that it is possible, the aforementioned upper layer, which may also be multi-layered, and / or the aforementioned lower layer, which may also be multi-layered, when solidifying / pressing the nonwoven fabric directly with the Carrier layer to connect. In the batch process, this means that in the mold first the lower layer, then the not according to the invention solidified nonwoven fabric and then the upper layer, optionally with their individual layers, are inserted and then the entire layer package is pressed. On the one hand, "directly connecting" means, in the continuous process, that the respective upper or lower layer is fed directly to the first pair of rolls used for the compaction or consolidation of the nonwoven fabric. At the same time it is also possible that the closing of the upper and / or the lower layer also takes place shortly after the first pair of rollers, which is possible until the continuously produced base plate is separated.

In this way, decor carriers or fabrics for surface finishing can be realized even in the pressing process. The process is very dimensionally accurate and true to detail.

Finally, the present invention relates to a pressing device for producing a plate of the aforementioned type, with an upper pressing part, a lower pressing part and a mold cavity.

In connection with the present invention, it is now provided that at least one contouring means is provided on the upper pressing part and / or on the lower pressing part for forming a tongue-and-groove connection formed at least in regions on the plate.

As has already been stated above, the pressing device may on the one hand be a short-cycle press for the discontinuous production or else a rolling device with at least one pair of rolls for the continuous production.

Both in the continuous and in the discontinuous pressing device is provided as contouring at least one profiling, for example in the form of corresponding projections, profile recesses and / or a projecting into the mold cavity movable mandrel or slider. By the use of the aforementioned mandrel, which is like a slider in the mold cavity and out of this movable, it is possible to provide an internal groove in compressing the nonwoven fabric for the production of the carrier layer in this.

Incidentally, at the upper and / or lower pressing part, regardless of whether the pressing device is a short-cycle press or a rolling device, such a contouring of the profiling may be provided which corresponds to the final groove and / or spring design of the Locking contour is at least substantially adapted.

In addition, the contouring means can be provided in the form of the profiling both in the longitudinal and in the transverse direction at the upper and / or lower pressing part, so that it is possible both in the continuous and in the discontinuous production, a pre-division of the base plate in the individual Make plates.

Other features, advantages and applications of the present invention will become apparent from the following description of exemplary embodiments with reference to the drawing and the drawing itself. In this case, all described and / or illustrated features, alone or in any combination, the subject of the present invention, regardless of their Summary in the claims or their dependency.

It shows

1 a perspective schematic representation of a plate according to the invention,

2 a perspective schematic representation of a furniture component plate,

3 a schematic sectional view of a portion of an embodiment of a plate according to the invention,

4 one of the 3 corresponding view of another embodiment of a plate according to the invention,

5 one of the 4 corresponding view of another embodiment of a plate according to the invention,

6 one of the 5 corresponding view of another embodiment of a plate according to the invention,

7 a schematic representation of part of an embodiment of a carrier plate according to the invention,

8th one of the 7 corresponding view of a further embodiment of a carrier plate according to the invention,

9 a schematic representation of a discontinuous pressing device according to the invention before pressing,

10 one of the 9 corresponding view of the pressing device 9 during the pressing process,

11 one of the 10 corresponding view of the pressing device 9 after completion of the pressing process,

12 a plan view of the lower pressing part of a pressing device according to the invention,

13 a schematic side sectional view of a continuous pressing device during the solidification process,

14 a schematic sectional view of a carrier plate from the solidified nonwoven fabric,

15 a profiled on the marginal edges carrier plate in a schematic sectional view,

16 a front view of the pressing device 13 .

17 one of the 16 corresponding representation of another embodiment of a continuous pressing device and

18 a side view of the pressing device 17 in a schematic representation.

In 1 is a plate 1 represented, which in the present case is a panel or a floorboard for a floor covering, not shown, which consists of a plurality of interconnected plates 1 composed. Ultimately, it is the plate 1 around a flooring panel. The plate 1 has a flat support plate 2 on, on the upper side and thus firmly connected an upper layer 3 is applied.

In 2 is a plate 1 shown, which is a furniture component plate. Also the in 2 illustrated plate 1 has a carrier plate 2 and an upper layer 3 on.

A difference between those in the 1 and 2 illustrated plates 1 is that the flooring panel off 1 edge has a locking contour, while such a contour on the furniture component plate edge is not provided. The edges at the in 2 represented plate 1 extend at least substantially at right angles to the top or bottom of the plate body.

The one at the plate 1 out 1 On the edge provided locking contours have on one longitudinal side a protruding spring 4 and on the opposite longitudinal side a corresponding, complementary groove 5 on. Furthermore, located on the one short side of the otherwise rectangular plate 1 also a spring 4 , while on the opposite short side of a corresponding, complementary groove 5 is provided. The tongue and groove connection on the longitudinal and short sides, which can also be referred to as a bung connection or bung, can in principle be identical. In the case of a click connection, however, they are designed differently.

The feather 4 and the groove 5 are presently provided for the formation of a so-called click connection with the result that the spring 4 in the groove 5 an adjacent plate can be snapped when laying. In practice, the installation is usually done by obliquely applying the plate to be laid 1 to an already laid plate 1 , This results in a preliminary engagement of the spring 4 in the groove 5 , Subsequently, the plate to be laid is swung down, so that the locking results over the click connection. At the same time there is a connection on the short sides, after the plate to be laid 1 to already laid plates 1 has been pushed.

It is now planned that the plate 1 regardless of whether it is a floor covering panel, a furniture component panel or a wall cladding or ceiling cladding panel, the support panel 2 made of a consolidated non-woven fabric, which is in particular needled. In the illustrated embodiment, the nonwoven fabric at least predominantly natural fibers. In addition, the nonwoven fabric is impregnated with a binder. In this case, the weight fraction of the binder based on the weight fraction of the nonwoven fabric is about 1: 3. In the specific embodiment shown, the consolidated nonwoven fabric has a density in the range of 760 kg / m ³ , while it is also possible carrier plates 2 to use with a sufficient strength, which have a much lower density. Thus, in another alternative embodiment, a density in the range of 410 kg / m ^{3 is} provided. Incidentally, the material of the carrier plate according to the invention can be 2 describe in that the degree of compaction of the unconsolidated nonwoven fabric to the inventively solidified nonwoven fabric is in the range of 4.7.

In the 3 to 6 are possible embodiments of the plate according to the invention 1 shown.

In all the illustrated embodiments, on the one hand, an upper layer 3 , which is multi-layered in all embodiments, and otherwise a lower layer 6 intended. Here is the bottom layer 6 at the in the 3 and 4 embodiment shown in one layer, while in the in the 5 and 6 illustrated embodiments is formed in two layers.

It will of course be understood that in all the illustrated embodiments it is also possible to have a greater or lesser number of layers in the upper layer 3 or the lower layer 6 provided.

At the in 3 illustrated embodiment, the upper layer 3 an outer layer 3a which may be a vinyl / PUR / PP wear layer. Below the outer layer 3a there is another layer 3b , which is a printed decorative paper. Not shown is that the further layer 3b via an adhesive layer with the carrier plate 2 connected is. Incidentally, an adhesive layer between the further layer 3b and the outer layer 3a be provided.

Instead of training the further shift 3b As decorative paper, it can be in the other layer 3b also act on a printed vinyl carrier. If necessary, then the aforementioned not shown adhesive layers are provided.

In principle, it is also possible that the outer layer 3a is designed as a corundum overlay, under which there is a printed decor paper layer that is impregnated, that is called entarzt. The connection to the carrier plate 2 then takes place over the resin of the further layer 3b ,

Alternatively, it is also possible that the upper side as an outer layer 3a a lacquer / corundum layer is provided which is applied to an underlying paper or vinyl carrier layer.

At the in 4 illustrated embodiment, the outer layer 3a on a trained as a protective overlay further layer 3b applied to another layer 3c followed. At the shift 3b In the exemplary embodiment illustrated, it may be a protective overlay that is based on a resinated, printed decorative paper layer as a further layer 3c is applied.

In principle, it is also possible that the outer layer 3a a textured paint layer is while the further layer 3c may be a printable nonwoven that is solidified or not solidified. On the nonwoven layer as another layer 3c is then a digital print as another layer 3b applied. Instead of the printable fleece as another layer 3c It is also possible to provide a print plating layer, for example in the form of a primer.

It should be noted that the individual layers shown are always shown with omission of any necessary adhesive layers. The adhesive layers are not to be understood as sub-layers within the meaning of the invention.

The in the 4 and 5 illustrated embodiments correspond to those in the 3 and 4 illustrated embodiments, at least as far as the upper layer 3 is affected. One difference is that in the embodiments of the 3 and 4 the lower layer 6 one-layered, while in the 5 and 6 is formed in two layers.

In the single-layered design is as the lower layer 6 For example, a return made of cork provided. In the two-layered embodiment, a nonwoven layer can be provided in addition to the cork layer, which then is a nonwoven fabric not consolidated in accordance with the invention. The order of arrangement of the cork layer and the fiber fleece layer is arbitrary.

In principle, a paper layer could also be provided in return for itself or in conjunction with one or both aforementioned layers.

In the 7 and 8th is in each case schematically a part of a carrier plate 2 shown. At the in 7 illustrated embodiment, the support plate 2 two-layered and has an upper layer 2a and a lower layer 2 B on. In the illustrated embodiment, each is the same nonwoven material, wherein the upper layer 2a is more compressed than the lower layer 2 B , The lower layer 2 B is thus softer than the top layer 2a , In the 7 illustrated embodiment is particularly suitable when a soft ride is to be generated. The upper layer takes care of that 2a then for a pressure distribution across the surface of the plate 1 while the shift 2 B Provides cushioning when running / walking due to its better compressibility and lower hardness.

At the in 8th illustrated embodiment, the properties of the carrier plate 2 out 7 about the properties of another layer 2c extended. However, other dimensions have been deliberately used. The layer 2c has a high degree of compaction and a high thickness. This is realized because the layer 2e used to form the locking contour. Accordingly, the thickness of the layer 2c greater than the maximum height of the groove 5 so that the groove 5 in the layer 2c can be trained.

In the 9 to 11 is schematically a part of a pressing device 7 shown. The pressing device 7 has an upper pressing part 8th and a lower pressing part 9 on. Between the upper pressed part 8th and the lower pressed part 9 there is a mold cavity 10 , In the in the 9 to 11 shown pressing device 7 it is a so-called short-cycle press, which works discontinuously. It is envisaged that both the upper pressed part 8th as well as on the lower pressed part 9 Contouring means for forming an at least partially on the plate 1 trained tongue and groove connection are provided. Specifically, it is in the illustrated embodiment, that at the upper pressing part 8th a profiling 11 is provided, which the upper region or the upper contour of the spring 4 maps. At the bottom press part 9 there is also a profiling 12 , on the one hand a part of the spring 4 and on the other hand a part of the groove 5 maps. Furthermore, it is located at the bottom press part 9 a movable spike 13 whose tip reaches into the mold cavity 10 is displaceable. The tip of the thorn 13 is profiled so that it matches the shape of the front end of the groove 5 equivalent.

Incidentally, goes from the 9 to 11 the procedure in the batch production of a carrier plate 2 out. First, a mat-shaped nonwoven fabric as a starting or base material in the mold cavity 10 of the lower pressed part 9 inserted. Subsequently, the upper pressed part 8th moved down. It shows the 9 only an intermediate state. The downward movement of the upper pressed part 8th takes place until the two pressed parts 8th . 9 on top of each other, as in 10 is shown. The nonwoven material is compacted during compression. The binder in the nonwoven material reacts under the influence of pressure and heat and solidifies the nonwoven material in the compressed state. In the illustrated embodiment, a degree of compaction results between 4: 1 and 5: 1. After a predetermined pressing time, the upper pressed part 8th moved up, as in 11 shown is. At the same time the thorn becomes 13 retracted so far that its tip no longer or only slightly into the mold cavity 10 protrudes. Subsequently, the solidified support plate 2 the pressing device 7 or the mold cavity 10 be removed.

It should be pointed out that instead of a movable thorn 13 basically a permanent in the mold cavity 10 protruding thorn could be provided. In this case, the solidified support plate would have to be inclined to the mold cavity 10 or the pressing device 7 be removed.

Furthermore, it should be noted that instead of in the 9 to 11 illustrated embodiment in the pressing device 7 not just a carrier plate 2 but also a plate 1 with the upper layer 3 and / or the lower layer 6 can be produced. Provided both an upper layer 3 as well as a lower layer 6 are provided, the lower layer is first 6 placed on the then non-compressed mat made of nonwoven fabric is placed. This in turn becomes the upper layer 3 hung up. The compression of the upper and / or the lower layer 3 . 6 with nonwoven material, then the carrier plate 2 forms, then takes place during compaction in the in 10 illustrated state.

Incidentally, it should be noted that in principle it is also possible, instead of just a single plate 1 or support plate 2 also to produce a base plate, which after the solidification of the fiber web into a plurality of individual plates 1 or carrier plates 2 is split.

In 12 is a plan view of a lower pressing part 9 a pressing device 7 shown with a base plate with 16 individual plates 1 can be produced. The lower pressed part 9 has a number of contouring agents in the form of profilings 14 on, which are longitudinal and transverse projections, which ultimately the rectangular shaped plates 1 predefine. On the upper side, the profiles are at least partially to the shape of the locking contour, that is the spring 4 and / or the groove 5 the plates 1 , customized. To the in 12 shown lower pressed part 9 corresponds to an unillustrated upper pressing part, the distribution of the division of the in 12 shown lower pressed parts 9 corresponds, but the profiling provided there not necessarily correspond to the profiles on the opposite pressing part, but to the top-side profiling of the spring 4 are adjusted.

Incidentally, it is understood that the illustrated embodiment of the lower pressed part 9 is only an example. Basically, the lower pressed part 9 any number and shape of shelves for plates 1 exhibit.

In 13 is schematically a continuously operating pressing device 7 shown. This points as upper and lower pressing part 8th . 9 one roller each, which in the present case in each case a profiling 14 having. However, it should be noted that the profiling 14 , Which represents the shape of a circumferential projection with an on-demand precontouring in adaptation to the profile of the tongue and groove joint, can basically be omitted, so that only smooth, cylindrical rollers are used.

From the 13 also schematically shows the type of solidification. The pressing device 7 or the rollers is supplied with a binder impregnated or thermoplastic fibers having nonwoven material which is compacted for solidification. Here, too, a solidification takes place under a predetermined pressure and a predetermined temperature, with a degree of compaction of between 4: 1 and 5: 1 also being achieved here.

In 14 is the after the procedure off 13 produced carrier plate 2 shown schematically after the production by the pressing device 7 has been separated from the produced strand of material. It is understood that according to the method 13 individual carrier plates 2 but also base plates, which subsequently into individual plates 1 be divided, can be produced. Incidentally, it is also possible in the continuous process, not only the carrier plate 2 via the pressing device designed as a rolling device 7 but also the plate 1 as such. Here then runs directly to the pair of rollers 8th . 9 the upper layer 3 and / or the lower layer 6 to or else the running of the individual layers 3 . 6 takes place after the roller pair and before separation of the base plate / plate 1 / Carrier plate 2 ,

While the in 14 illustrated carrier plate 2 basically as a furniture component can be used, then the top side with the upper layer 3 and underside with the lower layer 6 is provided and can also be provided at the edge with appropriate layers is in 15 a carrier plate 2 shown, which is processed on the edge and on the corresponding locking contours via a spring 4 and a groove 5 are provided. Then can then on top of the carrier plate 2 the upper layer 3 and underneath the lower layer 6 be provided. At the in 14 illustrated embodiment, which is particularly suitable as a furniture component plate, can be provided that upper and On the underside and edge edge side a paint coating is provided as a layer.

In 16 is a front view of the pressing device 7 out 13 shown. Visible are the two outer profiles 14 as well as the intermediate central profiling 14 on the rollers. Although this is not shown in detail, the profiles are 14 formed at their ends not V-shaped, but at least partially correspond to the contouring or the profile of the tongue and groove joint on the top and bottom of the plate 1 ,

The embodiment according to 17 is different from the one in 16 in that on the rollers formed as pressed parts 8th . 9 in addition to the longitudinal direction of rotation profilings 14 additional transverse profiles 15 are provided, which are ultimately the plates 1 or carrier plates 2 define a base plate to be produced. Also the transverse profiles 15 are on their top to the profile or the contour of the locking contour of the plate 1 at least partially adjusted.

18 shows a transverse view of the pressing device 7 out 17 ,

LIST OF REFERENCE NUMBERS

1

plate

2

support plate

2a

upper layer

2 B

another layer

2c

another layer

3

upper layer

3a

outer layer

3b

another layer

3c

another layer

4

feather

5

groove

6

Lower class

7

presser

8th

upper pressed part

9

lower pressing part

10

mold cavity

11

profiling

12

profiling

13

mandrel

14

profiling

15

profiling

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 29724428 U1 [0002]

Claims (10)

Plate ( 1 ) for a floor, wall or ceiling covering or for a furniture component, preferably floor covering, wall cladding or ceiling cladding panel or furniture component panel, with a flat support plate ( 2 ) and one on the carrier plate ( 2 ) applied top layer ( 3 ), characterized in that the carrier plate ( 2 ) is made of a consolidated nonwoven fabric or that the support plate ( 2 ) has at least one layer of a consolidated nonwoven fabric. Plate according to claim 1, characterized in that the nonwoven fabric is made of vegetable fibers, animal fibers, natural polymer fibers, synthetic polymer fibers, mineral fibers and / or recycled fibers and / or that the nonwoven fabric is mechanically, chemically and / or thermally solidified. Plate according to claim 1 or 2, characterized in that the nonwoven fabric is impregnated with binder and / or comprises thermoplastic polymer fibers, and that, preferably, the carrier plate ( 2 ) has a larger proportion of nonwoven material and a smaller proportion of binder and / or thermoplastic polymer fibers, preferably a smaller proportion of binder and / or polymer fibers of not more than 50%, in particular not more than 30%. Plate according to one of the preceding claims, characterized in that the material of the carrier plate ( 2 ) has a density between 350 kg / m ³ and 1000 kg / m ³ , in particular between 400 kg / m ³ and 900 kg / m ³ and preferably between 750 kg / m ³ to 850 kg / m ³ and / or that the basis weight the carrier plate ( 2 ) per mm thickness between 500 and 1500 g / m ² , preferably between 750 and 1250 g / m ² and in particular between 850 g / m ² and 950 g / m ² and / or that the degree of compaction of the unconsolidated nonwoven fabric to solidified nonwoven fabric between 10: 1 and 2: 1, preferably between 7: 1 and 3: 1 and in particular between 5: 1 and 4: 1. Plate according to one of the preceding claims, characterized in that the carrier plate ( 2 ) at the edge a tongue and groove contour, in particular in the form of a click connection, and / or that the carrier plate ( 2 ) is more strongly solidified in the region of the tongue and groove contour than outside the region of the tongue and groove contour. Plate according to one of the preceding claims, characterized in that the carrier plate ( 2 ) is formed multi-layered and / or that at least two layers of the carrier plate ( 2 ) have a different Kompaktierungs- and / or solidification and / or that the support plate has at least one layer of HDF and / or MDF. Method for producing a plate ( 1 ) for a floor, wall or ceiling covering or for a furniture component, preferably floor covering, wall cladding or ceiling cladding panel or furniture component slab, the slab ( 1 ) a flat support plate ( 2 ) and one on the carrier plate ( 2 ) applied top layer ( 3 ), characterized in that the carrier plate ( 2 ) from a non-woven fabric by solidification by means of a pressing device ( 7 ) will be produced. A method according to claim 7, characterized in that a tongue and groove connection at least partially in the pressing device ( 7 ) is pressed and / or that at least one precontouring of the tongue and groove connection in the pressing device ( 7 ) and / or that the plate ( 1 ) or support plate ( 2 ) is profiled edge, in particular after splitting a base plate for the particular final creation of the tongue and groove contour. Method according to claim 7 or 8, characterized in that the carrier layer ( 2 ) when solidifying / pressing the fiber fleece with an upper layer ( 3 ) and / or a lower layer ( 6 ) is connected. Pressing device ( 7 ) for the production of plates ( 1 ) for a floor, wall or ceiling covering or for a furniture component, preferably a floor covering, wall cladding or ceiling cladding panel or furniture component slab, having an upper pressing part ( 8th ), a lower pressing part ( 9 ) and a mold cavity ( 10 ), characterized in that on the upper pressed part ( 8th ) and / or at the lower pressing part ( 9 ) at least one contouring means for at least partially shaping one on the plate ( 1 ) or support plate ( 2 ) provided tongue and groove connection is provided.

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