DE202013011974U1 - floorboard - Google Patents

Abstract

Floor board (1, 2), which has a carrier plate (3, 19) with an upper-side veneer (4, 20, 21, 29, 30), wherein the carrier plate (3, 19) and the veneer (4, 20, 21; 29, 30) are connected to one another via a resin (6, 26), characterized in that at least two side edges (12, 13; 22, 23, 31, 32) of the veneer (4, 20, 21, 29, 30) an edge strip (14, 15, 24, 25, 33, 34) is provided and the edge strips (14, 15; 24, 25; 33, 34) are made of resin (6).

Description

The invention relates to a floorboard, which has a carrier plate and a veneer applied to the carrier plate on the upper side, wherein the carrier plate and the veneer are connected to one another via a resin.

Floor boards with a wear layer of real wood are used in particular as real wood floors or parquet floors. A method for producing parquet or floorboards with a wear layer of real wood, there referred to as cover layer, is in the DE 102 45 914 A1 described. Here, the top layer of real wood is subjected to impregnation with thermosetting resins and printed the top layer.

Common are real wood floorboards with a three-layer structure and profiled joining surfaces, the so-called click system. This allows for mechanical connection and locking along the abutting edges of the floorboards. The carrier plate usually consists of a high-density fiberboard (HDF). The click connection is milled into the carrier plate. As a wear layer a wood veneer is laminated on the support plate. The wood veneer can be different in thickness. With a thickness of the wood veneer of about 0.6 mm is called a real wood or veneer floor. For a parquet floor, the wear layer is at least 2.5 mm thick.

The visible surface of a floor panel with a top-class wear layer of real wood shows the naturalness and elegance of real grown wood. The appearance of the floorboards varies according to the variety of different types of wood. Nevertheless, there is a need to expand the look and variation possibilities of the visible surfaces of the real wood. The same applies to veneers made of cork.

The preparation of the veneers is also expensive. These are assembled from strips and glued or sewn together. In this way, one obtains a large format of the wood veneers matched to the large-format base plate. However, this preparation also requires a corresponding manufacturing overhead.

Furthermore, the wood veneers, but also cork veneers, are often trimmed generously at the edges to trim them and ensure a straight edge of the edge. This leads to a corresponding waste. Against this background, a greater conservation of resources is desirable.

Furthermore, it should be noted that the edge region along the side edges of the veneer is particularly stressed. Especially in the use of wood veneers made of soft wood species may arise in the edge area problems both in the processing of the panels in the course of further manufacturing steps such as brushing or grinding or by abrasion in the course of the intended use in a floor space.

The invention is based on the prior art, the task of creating a floorboard with a top-side veneer, which is improved in terms of cost and manufacturing and application technology and has a striking appearance.

This object is achieved by a floorboard according to claim 1.

Advantageous embodiments of the floorboard according to the invention are the subject of the dependent claims 2 to 8.

In particular, the present invention relates to floorboards having a wood veneer thickness of less than 2.5 mm, in particular a thickness of between 0.6 mm and 1.2 mm. Likewise, the veneer may be a cork veneer, in particular a cork oak veneer.

The floorboard according to the invention has a carrier plate with a top-side veneer. The carrier plate is a plate material made of a wood material such as solid wood, chipboard, wood fiber material, MDF (Medium Density Fiberboard) or HDF (High Density Fiberboard). In practice, the carrier plate is made in particular of HDF. Also carrier plates made of other materials or mixtures of materials are suitable for practice. It can find support plates made of waterproof materials application, for. Based on mineral materials such as fiber-cement sand-binder mixtures or wood-plastic composites (wood-plastic composites WPC) and wood-fiber polymer composites. Also suitable are magnesite plates. One aspect here also aims at the use of natural fiber-reinforced plastic as the material for the carrier plate or the output carrier plate. In addition to wood fibers, other plant fibers such as jute or flax can be used. Here, a natural fiber or natural flour content of 50% to 90% in a plastic matrix preferably of polypropylene (PP) comes into play. Furthermore, a wood-plastic composite material based on thermoplastic thermosets such as modified melamine resin with natural fiber or natural flour content can be used. An approach that is interesting for practice also offers Bamboo Plastic Composite (BPC). With this material bamboo fibers or bamboo flour are used as natural material.

As already mentioned, it is also possible to use plates based on cementitious binders or fiber cement boards as support plates, as well as magnesite plates. 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 plates is their weight and low thermal conductivity, as well as their fire resistance. Magnesite plates are classified as non-combustible.

The carrier plate may also consist of elastic materials, for example nonwoven or nonwoven materials or based on cellulose. In this context, in particular relatively thin carrier plates with a thickness between 1 mm and 6 mm are used.

The carrier plate and the veneer are thermally pressed together by means of a resin and permanently bonded together. According to the invention, an edge strip is provided on at least two side edges of the veneer. This edge strip is made of resin. Preferably, an edge strip made of resin is formed on all sides around the veneer.

Preferably, the edge strip optically differs from the veneer. One can therefore distinguish the edge strip clearly from the veneer, but the edge strip is optically matched to the veneer. The edge strip has the basic color of the veneer, but is uniform in color. A variance in the optical design of a floorboard results when a resin is used, which is in color contrast with the color of the veneer. As a result, for example, a joint optics can be generated specifically. Through the interaction of resin and veneer, an optical accentuation of the surface of a floorboard is possible. For this purpose, effect materials such as pigments and other fillers can be used in the resin. An effect material may be, for example, mica. Also fluorescent pigments as effect material are possible.

The veneer is smaller in size than the carrier plate. As a result, the veneer does not completely cover the carrier plate. This results in at least two side edges of the veneer edge strips, which are formed by resin. The surface of the edge strips runs in the plane of the surface of the veneer. The resin fills the edge strips and equalizes the surface to the surface of the veneer.

One aspect of the invention provides that the veneer has odd side edges, in particular the side edges may be uncut. An otherwise usual waste is eliminated. This leads to a better utilization of the available raw material and a conservation of resources.

Starting product in the production of floorboards according to the invention is a large-scale output carrier plate. The output tray 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 carrier plate or the output carrier plate has a thickness of 4.5 mm to 12 mm.

The veneers are laid as strips or plates on a large-format output carrier plate. The individual arranged on the output carrier plate strips or plates of the wood veneer are spaced from each other, so that there is a gap between the individual veneers. Between the base plate and the veneers, the resin is incorporated. It is in particular a thermosetting synthetic resin. Colored or transparent melamine resins or melamine / polyurethane resin mixtures can be used. The resin may be present on a paper-like carrier in the form of a paper impregnate, also called resin paper. The resin or the resin layer may further be present or formed as a resin film. A resin layer may be formed by a resin film applied to the top of the support plate. Also, a resin layer may be formed on the bottom side on the veneers in the form of a resin film. In both cases, the resin is applied liquid to the carrier plate or the veneer and dried or precondensed. When the resin is applied to the veneer, the wood veneer is impregnated with resin. The amount of resin is sized so that a reliable bond between the output carrier plate and the veneer is formed and the gap between the veneers is filled and leveled.

The resin used in the invention is in particular a thermosetting synthetic resin. One aspect of the invention aims to use resins which react and harden under heat and pressure. In this context, the use of aminoplastic, thermosetting or reactive resins such as polyurethane (PUR) or thermoplastic polyurethane offers.

During production, the output carrier plate, the resin and the veneers are pressed together and connected to each other. Here, the veneer is infiltrated by the resin, preferably completely penetrated. The pressing takes place hot at a temperature of more than 100 ° C, in particular more than 120 ° C, preferably at a temperature between 180 ° C and 210 ° C. The pressing temperature refers to the temperature of the press plate of the press. This temperature is also at the contact surfaces of the press plate with the top of the veneer or the underside of the carrier plate.

On the underside of the support plate a Gegenzuglage is provided. This Gegenzuglage is joined during the pressing process on the underside with the carrier plate. For this purpose, the Gegenzuglage is positioned in the formation of the multi-layer body of output carrier plate, resin and veneer underside 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 pressing temperature is greater than or equal to (≥) 100 ° C, preferably the pressing temperature is between 180 ° C and 210 ° C. The pressing time at which the multilayer body is pressurized in the press is between 10 seconds and 60 seconds.

During the pressing process, the surface of the veneers can be given a structure, a pattern or ornaments by means of a structured sheet metal or a structural element. The structure may vary in the degree of gloss in partial areas. Furthermore, different structure depths are possible. The texture depth can be up to 0.6 mm. Based on the veneer strength, the structure may have a texture depth of 2/3 of the veneer thickness.

After pressing, the pressed multi-layer body is cooled and divided into individual planks. As already stated, the resin fills the gap between adjacent veneers and equalizes the area. The splitting of the pressed large-format multilayer body into individual planks takes place along or in the region of the gap between two veneers arranged adjacent to one another. Accordingly, the width of the individual veneers is matched to the width of a single floor to be split. The individual planks are profiled in a subsequent step on their side edges. The profiling is used in particular for the formation of connecting means such as tongue and groove or click connections on the longitudinal and narrow sides of the planks. Also, folds can be formed. Since the side edge portions of the planks are stabilized by the resin, machining of the side edges is advantageously possible. In particular, fraying of the upper-side wear layer of veneer can be avoided.

In the course of a mechanical processing of the side edges of a board, the edge strip made of resin is obtained in whole or in part.

In the pressing process, the resin is plasticized under the influence of temperature and penetrates or infiltrated into the wood veneer. Preferably, the resin completely penetrates the wood veneer to the top of the wood veneer. In the process, pores, cracks, gaps and / or imperfections in the wood veneer are filled with resin during the pressing process. The resin forms a permanent connection between the wood veneer and the carrier plate. A further advantage of the invention is therefore that two production steps, namely gluing and filling of the wood veneer are carried out together in one operation.

In particular, the pressing of the multi-layer body is carried out so that the veneer is impregnated with resin and visible after pressing resin on the surface of the veneer. In this context, color-matched resins are used in particular for the color of the veneer. Product technically, a black resin is universally applicable and advantageous. Conveniently, the pressing is carried out so that the surface of the veneer and thus the plank is afflicted with very little resin or no resin. Pores, cracks, crevices and other imperfections are visibly filled. However, there is no or at least very little excess resin on the surface. The pressed product then only needs to be brushed and, where appropriate, receives a surface lubrication or coating.

The resin may contain a filler or thickened with a filler. As a result, more mass is available to fill pores, cracks, gaps and / or defects. As a filler, organic or inorganic materials can be used, in particular mineral pigments, powders or powders as well as wood powder or wood flour.

The surface of the floorboard or the surface of the veneer and the surface of the side edges are subjected to a mechanical surface treatment after the pressing. As part of the surface treatment, in particular grinding or brushing of the surface takes place. Also, the surface can be mechanically shaped and structured. Since the top-side veneer is impregnated by the resin, the resistance, in particular the indentation resistance and resistance to abrasion is also increased. The high resistance is advantageous in a mechanical processing of the wood veneer. The impregnation of the veneer with resin also allows the use of softer veneers, such as wood veneers made of woods such as larch or coarse-pored woods.

Furthermore, a sealing of the surface is possible, for example by the application of a color, a stain, an oil or even a paint system. In this context, the surface may also be printed with a decor.

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

1 in an enlarged view, the region of the longitudinal side of two adjacent floorboards with corresponding locking means;

2 a section of two coupled floorboards;

3a schematically shows a plan view of a floor covering of floorboards according to the invention;

3b a plan view of a floorboard according to the invention and

3c two individual floorboards and a section of a floor covering formed from the floorboards also in plan view.

The 1 and 2 illustrate schematically the structure of floorboards according to the invention 1 respectively. 2 in their vertical plane. The figures, in particular as regards the thickness of the individual layers, are not to scale.

Each floorboard 1 . 2 has a carrier plate 3 on top of which is a veneer, namely a wood veneer 4 is applied. The carrier plate 3 and the wood veneer 4 are over a resin layer 5 made of resin 6 over the entire surface pressed and glued together. Lower side of the carrier plate 3 is a counter-situation 7 intended. On the long sides 8th . 9 the floorboards 1 . 2 are locking strips 10 . 11 intended. For floorboards adjacent to a floor covering 1 . 2 come the respective corresponding locking strips 10 . 11 engaged with each other. In the 1 as well as in the 2 are the locking bars 10 . 11 on two opposite longitudinal sides 8th . 9 a floorboard 1 . 2 shown. The floorboards 1 . 2 also have at their respective top sides locking means, which, however, are not visible here.

The carrier plate 3 and the top-side wood veneer 4 as well as the carrier plate 3 and the bottom-side counter-tension position 7 are thermally pressed together and glued together inseparably. The bonding between carrier plate 3 and wood veneer 4 via the incorporated resin 6 , Also the Gegenzuglage 7 is with the carrier plate 3 glued over a resin.

At the top of the floorboards 1 . 2 is on at least two margins 12 . 13 of the wood veneer 4 a border strip 14 . 15 educated. This edge strip 14 . 15 is made of resin 6 , The surface 16 the edge strip 14 . 15 runs in the plane of the surface 17 of the wood veneer 4 ,

When pressing the carrier plate 3 , Wood veneer 4 , Gegenzuglage 7 with each provided in between resin 6 (Resin layer, resin film) becomes the resin 6 plasticized. The top side provided resin 6 between carrier plate 3 and wood veneer 4 infiltrates the wood veneer 4 , Here, the resin 6 the wood veneer 4 to the surface 17 of the wood veneer 4 penetrate. This is in the 2 clarified.

In wood veneer 4 existing pores, cracks, crevices and / or imperfections are when pressed with resin 6 filled. There is the gluing of the wood veneer 4 with the carrier plate 3 and the filling of the surface 17 of the wood veneer 4 together in a single operation during the pressing of the multi-layer body.

An exemplified section of a floor covering formed from floorboards according to the invention 1 . 2 show the 3 in the plan view. The floorboards 1 . 2 are coupled to a floor covering. The margins 12 . 13 the wood veneers 4 each have a peripheral edge 14 . 15 made of resin 6 on. Pores, cracks, crevices and / or defects such as knotholes within the wood veneers 4 are with resin 6 filled. The surface 17 of the wood veneer 4 can be stained in color after printing or printed with decors or patterns. Subsequently, a protective layer or seal is applied, for example of transparent lacquer, floor oil or the like. Furthermore, it is possible to color print or paint the edges or side edges of the floorboard made of hard high-strength resin material.

The 3b shows a floorboard 18 , This has a support plate 19 and on top a number of wood veneers 20 . 21 on. As previously described, the carrier plate 19 and the wood veneers 20 . 21 thermally pressed together. Along the margins 22 . 23 the wood veneers 20 . 21 are edge stripes 24 . 25 Made of resin 26 consist. It can be seen that the surface of the floorboard 18 due to the geometrically diverse designed and arranged wood veneers 20 . 21 has a non-uniform character.

The 3c shows two single floorboards 27 . 28 and a section of a floor covering formed of floorboards 27 , 28 , The construction of the floorboards 27 . 28 is as previously described. The floorboards 27 . 28 have top-side wood veneers 29 . 30 , Each round at the side edges 31 . 32 are edge stripes 33 . 34 made of high-strength resin material.

Basically, the wood veneers 29 . 30 regularly but also irregularly arranged.

LIST OF REFERENCE NUMBERS

1

floorboard

2

floorboard

3

support plate

4

wood veneer

5

resin layer

6

resin

7

counteracting

8th

long side

9

long side

10

 locking bar

11

 locking bar

12

 margin

13

 margin

14

 edge strips

15

 edge strips

16

 surface

17

 surface

18

 floorboard

19

 support plate

20

 wood veneer

21

 wood veneer

22

Margin v. 20

23

Margin v. 21

24

 edge strips

25

 edge strips

26

 resin

27

 floorboard

28

 floorboard

29

 wood veneer

30

 wood veneer

31

 margin

32

 margin

33

 edge strips

34

 edge strips

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 10245914 A1 [0002]

Claims (8)

Floorboard ( 1 . 2 ), which a support plate ( 3 ; 19 ) with a top veneer ( 4 ; 20 . 21 ; 29 . 30 ), wherein the carrier plate ( 3 ; 19 ) and the veneer ( 4 ; 20 . 21 ; 29 . 30 ) over a resin ( 6 ; 26 ), characterized in that at least two side edges ( 12 . 13 ; 22 . 23 ; 31 . 32 ) of the veneer ( 4 ; 20 . 21 ; 29 . 30 ) a border strip ( 14 . 15 ; 24 . 25 ; 33 . 34 ) and the edge strips ( 14 . 15 ; 24 . 25 ; 33 . 34 ) made of resin ( 6 ) consist. Floor board according to claim 1, characterized in that the edge strips ( 14 . 15 ; 24 . 25 ; 33 . 34 ) visually from the veneer ( 4 ; 20 . 21 ; 29 . 30 ). Floor board according to claim 1 or 2, characterized in that the surface ( 16 ) the edge strip ( 14 . 15 ) in one plane to the surface ( 17 ) of the veneer ( 4 ) runs. Floorboard according to at least one of claims 1 to 3, characterized in that the veneer ( 4 ) odd margins ( 12 . 13 ) owns. Floorboard according to at least one of claims 1 to 4, characterized in that the resin ( 6 ; 26 ) in the veneer ( 4 ; 20 . 21 ; 29 . 30 ) is infiltrated, especially soaked. Floorboard according to at least one of claims 1 to 5, characterized in that on the underside of the support plate ( 3 ) a counter-position ( 7 ) is provided. Floorboard according to at least one of claims 1 to 6, characterized in that the resin ( 6 ) contains a filler. Floor board according to at least one of claims 1 to 7, characterized in that the surface ( 17 ) of the veneer ( 4 ) and / or the surface ( 17 ) the edge strip ( 14 . 15 ) are ground, embossed, brushed and / or sealed.

Images