DK2963204T3 - Plate for floor, wall or ceiling or for a furniture component and method for making such a plate - Google Patents

Description

PANEL FOR A FLOOR, WALL OR CEILING LINING OR FOR A FURNITURE COMPONENT AND METHOD AND PRESS DEVICE FOR PRODUCING SUCH A PANEL

The invention relates to a panel 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 plane substrate panel and an upper layer applied to the substrate panel.

Panels of the aforementioned type, which are also termed as planks or boards when it comes to the area of flooring, walls or ceilings, have long been known from practice. Panels of the aforementioned type for the area of flooring, walls or ceilings are usually provided at the edge with a tongue-and-groove connection in order to be able to lay them securely on the substrate to become an appropriate covering. Such connections are also known in practice as ploughed-and-grooved joints. So-called click connections are generally used as the joining technology of panels. Panels with click connections, which are generally connectable by means of a swivel movement and are latched together in the clicked state, are known for example from DE 297 24 428 U1. With the known panels, the substrate panel is generally made of MDF, HDF, plastic or a ground wood fibre bonded with a binding agent.

Substrate panels for laminates, which are made from MDF or HDF, are generally made of approx. 82% spruce or pine with a proportion of sawmill residue and approx. 11% urea resin, 5 to 7% water and 1% paraffin wax. The substrate panels are produced, transported, separated and grooved at considerable expense. The chippings arising thereby are usually thermally recycled. With the known laminates or panels used therefor, it is disadvantageous that the panel production is on the whole relatively expensive and that a relatively high proportion of new wood is used for the production of HDF/MDF. A carpet flooring element is known from DE 20 207 844 U1. The carpet flooring element has a rectangular substrate panel, on the top side of which a correspondingly dimensioned carpet material is secured. A fleece layer can be provided on the underside of the substrate panel to compensate for unevenness. DE 10 2013 101 797 A1 discloses a panel for a laminate or parquet floor covering. The panel has a substrate panel, which comprises a load distribution layer. In addition, a fleece can be attached to the underside of the panel, said fleece consisting of glass fibres, textile fibres or plastic. DE 10 2012 112 562 A1 relates to a flooring element with a substrate panel made of highly compressed cork. A decorative layer is also applied to the substrate panel as the upper layer, wherein between the substrate panel and the decorative layer a sheet substrate material, for example a fleece, can be provided. WO 2014/053186 A1 relates to a floor panel for the outdoor area. The floor panel has a panel, which is for example formed by a fibrous cement panel. A glass fibre fleece can also be provided on the underside of the substrate panel. A panel for insulation or decorative purposes is known from US 3,661,491. To produce the panel, a thread from a binder with glass fibre being distributed therein as a loose mass is continually fed into a pressing device. In a press nip of the pressing device, a consolidation and shaping of the thread occurs under heat exposure, such that a substantially usable panel exists after passing through the press nip.

The object of the present invention is now to provide a panel of the above described type and a method relating to this, whereby it is possible to produce panels of the aforementioned type easily, cost-effectively and in an ecologically sustainable manner. This aforementioned object is achieved through the features of claim 1 with a panel of the above described type according to the invention.

The panel according to the invention has a substrate panel and an upper layer applied to the substrate panel. The upper layer can be formed as a single layer or as multiple layers. The upper layer can have a decorative layer and/or a wear layer. The decorative layer can be applied to a decorative substrate. The upper layer then has the decorative substrate with the decorative layer and the wear layer. The decorative substrate can be a printable (decorative) paper and/or a fleece layer and/or a substrate layer, preferably a film made of plastic, particularly vinyl, PVC, PUR, PE or PP. If a fleece layer is provided as the decorative substrate, this can be pressed with the substrate panel. In principle, a primer can also be applied as a decorative substrate to the substrate panel. The decorative layer is then applied to the primer. The wear layer can be made from a plastic, preferably from vinyl, PUR, PP, PE, or an oxidative or UV coating. Otherwise, adhesive layers can be provided between the decorative substrate and the wear layer and/or between the decorative substrate and the substrate panel. A stabilising layer of cork or a plastic material can be provided beneath the decorative substrate.

The transverse tensile strength of the substrate panel according to the invention according to EN 319 can be within the range of 1.0 to 4.0 N/mm2, particularly within the range of 1.4 to 2.5 N/mm2. The surface soundness according to EN 311 can be within the range of 1.0 to 4.0 N/mm2, preferably within the range of 1.5 to 2.8 N/mm2. The pull-out resistance where a click connection exists referring to ISO 24334 can be within the range of 1.0 to 6.0 kN/m, preferably within the range of 2.5 to 5.0 kN/m. The pull-out resistance is a value related to the length of the click connection, particularly related to a panel thickness of 1.0 cm or less. For example, 2.5 kN is required to pull apart a click connection of a metre in length. The aforementioned ranges can also be exceeded for the substrate panel according to the invention for the transverse tensile strength and/or the surface soundness and/or the pull-out resistance. A non-woven fabric of the type according to the invention is understood to be a structure of fibres of limited length, continuous fibres, which are also known as filaments, or cut fibres of any type and origin, which have been bonded or interconnected into a fleece in any manner. The length of the fibres for natural fibres tends to be 30 to 90 mm, the length for synthetic fibres tends to be between 50 and 70 mm.

Non-woven fabrics are usual flexible, textile surface structures made of fibres, which have a comparatively slight thickness in comparison with their length and width.

In relation with the present invention, it was surprisingly determined that a consolidated, needled non-woven fabric can readily fulfil the requirements usually placed on a substrate panel, such as strength and stability. In addition, the use of a consolidated non-woven fabric as the material of the substrate panel offers other significant advantages.

Firstly, a non-woven fabric is an alternative material to wood or wood composites as the material of the substrate panel, which is very cost-effective and more ecologically sustainable. In addition, the consolidated non-woven fabric offers very good acoustic and sound insulating properties, which when using a substrate panel made of wood composite can only be achieved if a sound insulating mat is additionally provided with the laminate in question. In addition, a different walking sensation can be produced for the user through the degree of consolidation of the non-woven fabric. With a less consolidated non-woven fabric, a softer walking sensation occurs, while with a strongly solidified non-woven fabric a similarly hard walking sensation is produced as when using a substrate panel made of wood.

Furthermore, it has been shown that the processing and handling of non-woven fabric substrate panels is a great deal easier than with a substrate panel made of a wood composite. In the first instance, significantly deeper structures can be achieved by pressing the fleece as the substrate panel in combination with resinous papers as the decorative layer, if the surface structure is directly compressed during the pressing procedure of the substrate panel. In addition, it is possible in principle to at least preform or profile the tongue-and-groove or click geometry at the edge of the panel such that the profiling effort and the associated costs can be reduced. Ultimately, a substrate panel made from a consolidated non-woven fabric has in comparison with a substrate panel made of a wood composite improved thermal insulation properties, which can only be realised with a substrate panel made of a wood composite by means of a supplementing thermal insulation layer.

The aforementioned advantages arise at least in part if the substrate panel has at least one layer made from a consolidated non-woven fabric. With this alternative, the supporting layer can exist only partially of a consolidated non-woven fabric, not completely. Thus for example a layer can be provided from a consolidated non-woven fabric and one layer from HDF or MDF. A sandwich structure with an internal HDF or MDF layer and outer solidified non-woven fabric layers is just as possible as an internal consolidated non-woven fabric later and outer HDF or MDF layers.

In principle, the non-woven fabric used for the substrate panel according to the invention can be made from any fibres that are usually used to manufacture fleece. Thus plant-based, animal-based, mineral and/or recycled fibres and fibres from natural and/or synthetic polymers are possible in principle. It is understood that compounds of the aforementioned fibres in any combination are also possible. If synthetic fibres are used, these consist primarily of PP and/or PET and/or PE.

In a preferred embodiment of the present invention, which focuses particularly on ecological sustainability and thus takes into account that a considerably amount of waste arises when producing substrate panels, which should preferably be easy to recycle, it is provided that the non-woven fabric should consist at least predominantly of plant-based fibres, particularly from sustainably produced flax, kenaf and/or hemp fibres.

In a particularly preferably embodiment, a non-woven fabric made from a fibre compound is used for the production of substrate panels, which has between 10 and 30 wt.-%, preferably between 20 and 25 wt.-%, plastic fibres, particularly of PP and/or PE. The fibre compound can also have flax and/or kenaf fibres and/or other fibres. If this fibre mix is highly compacted, a very high water resistance is achieved as compared with HDF panels. In the consolidated state, the density of the compacted fibre compound after pressing can preferably be in the range between 700 and 900 kg/m3.

To consolidate the non-woven fabric according to the invention, all known bonding methods can be used in principle, which are also used when manufacturing fleece from a raw fibrous material. The methods of mechanical, chemical or thermal consolidation can be used individually or in combination.

When mechanical consolidation, the composite of fibres is produced by means of frictional connection or a combination of frictional connection and form fitting. With frictional bonding, the distance to the neighbouring fibres in the base fleece material is reduced by means of fleece compaction. Thus the adhesion of fibres to each other is increased and higher forces can be transferred. The resistance of the non-woven fabric to deformation becomes higher, wherein it simultaneously becomes more solid. The compaction can be achieved for example by shrinking all fibres or a proportion thereof, if the fibres are shrinkable upon exposure to heat. Likewise, the compression can occur by means of pressing for example using roll compaction or fulling, wherein the fibres of the fleece according to the invention must be feltable and become felted to each other through simultaneous thermal, chemical and mechanical effects.

With the fleece materials resulting from the combination of frictional and form fitting bonding, the fibres of the fleece according to the invention are entwined with each other through mechanical exposure. This occurs through needling, with which a number of special needles being arranged in a needle bed or needle bar is pierced and withdrawn. With the chemical consolidation process, the composite of fibres is achieved by an adhesive bond using additives. The connection of fibres using additives, which are usually called binders, is also known as adhesive bonding. With a predominant number of chemical procedures, the binder is applied in liquid form (e.g. polymer dispersion) on or into the non-woven fabric and hardened through subsequent heat treatment (drying, condensation, polymerisation), wherein the fleece is consolidated. The application of liquid binder can for example occur by means of impregnation or spraying. Typical binders can for example be acrylic resins, epoxy resins and/or melamine resins.

With thermal consolidation, the composite of fibres is also produced by means of adhesive bond, wherein however there is a difference between adhesive and cohesive bonding. The prerequisite for thermal consolidation are thermoplastic additional components, particularly in the form of thermoplastic fibres. A thermal-mechanical consolidation of the fibre composite is preferably provided, wherein a fibre composite is compressed under the influence of heat following prior needling of the fibres, particularly in a double-belt press/belt press with pre-heating to heat the material. The fibre composite particularly has plastic fibres, particularly PP and/or PE fibres. The fibre mix can also include hemp and/or flax and/or kenaf fibres. By adding heat before and/or during the compression of the fibres, the fibres can fuse at least in some regions, which leads to a high strength of the connection of fibres during compression.

To consolidation the fibre composite, double-belt presses/belt presses with pre-heating to heat the fibrous material can preferably be used.

In connection with the present invention, it has also been shown that very good consolidation properties are then achieved if the non-woven fabric is soaked with binder, i.e. impregnated, and/or thermoplastic polymer fibres are contained in the non-woven fabric.

During trials in connection with the present invention, it was determined that very good properties of the substrate panel consisting of consolidated non-woven fabric are then achieved if the substrate panel has a larger proportion of consolidated non-woven fabric and a smaller proportion of binder and/or thermoplastic polymer fibres. The proportion of binder and thermoplastic polymer fibres is preferably no more than 50%, particularly 40% and further particularly no more than 30 wt.-%. It is even possible to reduce the proportion of binder to 20 wt.-% or even less. In a particularly preferably embodiment of the invention, a mass ratio within the range of 75 wt.-% of non-woven fabric material and 25% of binder or thermoplastic polymer fibres was used.

Furthermore, it was determined that the proportion of binders can differ depending on the type of binder. Thus the percentage proportion of thermoplastic binders with the same panel density and stability should be higher that the percentage proportion required for resins as the binder.

In connection with the present invention, it was further determined that it is particularly preferably as the starting material of the non-woven fabric according to the invention if this is not yet in the consolidated state according to the invention to use a fleece material, the density of which should be between 80 kg/m3 and 300 kg/m3, preferably between 100kg/m3 and 210 kg/m3 and particularly between 150 kg/m3 and 170 kg/m3. In the consolidated state according to the invention, the density of the non-woven fabric is between 400 kg/m3 and 1000 kg/m3, particularly between 400 kg/m3 and 900 kg/m3 and particularly preferably between 750 and 850 kg/m3.

It should be noted in this context that it is completely possible to form the substrate panel using multiple layers, wherein one layer of the substrate panel can have a greater density than the other layer. This shall be further detailed below.

In connection with the selection of the fibre according to the invention for the intended purpose to use as a substrate panel, the compacting ratio of the unconsolidated non-woven fabric to consolidated non-woven fabric is between 10:1 and 2:1, preferably between 8:1 and 4:1, further preferably 7:1 and 4:1, and particularly between 5:1 and 4:1.

Furthermore, in relation with the strength and stability investigations, it was determined that the substrate panel 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 substrate panel is preferably between 5 and 30 mm.

Furthermore, the substrate panel according to the invention when used in the area of flooring, walls and ceilings, as has already been pointed out at the start, has a tongue-and-groove contour at the side preferably in the form of a click connection. When pressing the fibre compound, particularly after prior heating of the fibrous material with the possibility of fusing areas of the fibrous material, a substrate panel is obtained having a substantially consistent strength over the panel thickness as compared to HDF panels. In particular, the fibre panels according to the invention have no soft central layer, like HDF panels, which makes it possible to insert a stable click contour, even in panels with a comparatively lower bulk density. In this context, the pull-out resistance of a click connection of the substrate panels according to the invention can based on ISO 24334 assume or even exceed a value between 1.5 and 6.0 kN/m2, preferably between 2.5 and 5.0 kN/m2.

In a particularly preferably embodiment of the invention, it is provided that the substrate panel is consolidated more strongly in the area of the tongue-and-groove contour than outside the area of this contour. In this way, the locking profile can be designed to be considerably more stable and the risk of damaging the groove and/or tongue is reduced. The substrate panel is preferably formed as multiple layers and/or has at least two layers with a different level of compaction and/or consolidation. Alternatively or in addition, the substrate panel can have at least one layer made of HDF and/or MDF.

The higher consolidation level in the area of the connecting contour can be realised in different ways. Firstly, it is possible to use a multi-layer substrate panel - as already mentioned -, wherein a more strongly consolidated non-woven fabric layer is used in the area of the locking contour. The thickness of this sublayer of the substrate layer is at least slightly greater than the maximum height of the groove of the locking contour, such that the groove can be formed completely within this more strongly consolidated substrate layer. A further alternative exists in more strongly consolidating the non-woven fabric in the area of the locking contour. This area can be more strongly consolidated during the production of the substrate panel in order to achieve a strong consolidation in this way.

It should be noted that the two aforementioned alternatives can also be used in combination with each other.

Furthermore, it has been determined according to the invention that further positive effects can be achieved by the multi-layered effect of the substrate panel. A multi-layered substrate panel in the sense of the invention shall be assumed if the substrate panel has at least two layers having a different level of compaction and/or consolidation. However, substrate panels with three, four, five or an even greater number of individual layers is possible, wherein the individual layers can all have different levels of compaction and/or consolidation in principle. However, there are hereby at least two groups of layers, wherein the one group has a higher level of consolidation and compaction and/or the other group has another level concerning this.

Furthermore, it is understood that the different layers of the substrate panel can be produced not only from one, but rather a variety of, non-woven fabrics.

As well as achieving a specific stability of the locking contour or as an alternative to this, a different flexible behaviour of the panel can also be realised by selected different layers of the substrate panel. If for example a layer with a less strongly consolidated non-woven fabric is used in combination with a layer with a more strongly consolidated non-woven fabric, a walking sensation perceived by the user to be very pleasant can thereby be achieved. With such an embodiment, a more strongly consolidated non-woven fabric should be realised as the upper layer of the substrate panel, while a layer with a less strongly consolidated non-woven fabric is used underneath. In this way, a substrate panel could be constructed for example to have three layers, which comprise an upper, relatively strongly consolidated layer, a subjacent, less strongly consolidated and therefore more flexible layer and below this another more strongly consolidated layer, within which the locking contour is formed. The individual layers, as stated previously, can thereby consist of the same non-woven fabric, wherein the stronger consolidation is only produced on the basis of different compaction, however, different non-woven fabric materials can also be used, which fulfil the aforementioned effect and function.

As stated above, it can also naturally be provided that there is, for example, a 3 mm thick internal HDF or MDF layer and a consolidated non-woven fabric layer is arranged above and below. In this embodiment, the locking contour can then be provided in the central HDF or MDF layer.

Furthermore, in connection with the present invention, it was determined that it is advantageous if the upper layer is also formed of multiple layers. Thus the upper layer can have a printed, resinous or non-resinous paper layer, particularly a decorative paper layer, a protective overlay, particularly made of corundum, an outerwear layer made of plastic, particularly vinyl, PUR or PP, a printed plaster substrate, particularly made of vinyl, a lacquer layer, particularly a textured lacquer layer, and/or a printed fleece layer. In this context, it is possible during the needling of the non-woven fabric being used to produce the substrate panel to apply on the upper face another layer of another or the same fleece material to the substrate layer. A printable layer is thereby directly created. It is understood that combinations of the aforementioned layers with one or a number of the aforementioned alternatives are readily possible.

By realising the upper layer in the aforementioned manner, a panel can ultimately be produced, which should not differ on the outer face or in the fitted state from the panel known from the prior art having a substrate panel made of a wood composite, but which additionally has the previously mentioned improved properties and offers advantages. Furthermore, the panel according to the invention has a lower layer, which is applied to the substrate layer on the underside. This lower layer can have different properties or guarantee functions. Firstly, the lower layer can act as a counter beam or binding beam in order to avoid any unwanted distortion of the substrate panel according to the invention. In addition, supplementing sound insulating and acoustic properties can be achieved by a lower layer, said properties exceeding the advantageous sound insulating and acoustic properties already achieved by realising the invention. For example, a lower layer made of cork can be provided. However, the lower layer can also consist of a fleece material in principle, which is however not consolidated in the manner according to the invention. Furthermore, it is understood that the lower layer can also be structured with multiple layers if this is required for the specific applications.

In addition, the present invention relates to a method for the production of a panel 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, wherein the panel has a plane substrate panel and an upper layer applied to the substrate panel.

As previously stated, the panel production occurs in the prior art such that the substrate panels made of a wood composite are produced at a considerable expense.

The invention now goes another way, wherein a consolidated, needled non-woven fabric is produced for the production of the substrate panels. Reference is explicitly made to the previously mentioned advantages arising through the use of the consolidated non-woven fabric for the substrate panel.

In the invention, the previously described mechanical, chemical and/or thermal consolidation of the non-woven fabric can be realised in connection with the production of the substrate panel both by means of a continual or discontinuous method. In doing so, the continual production can preferably occur on a roller device, wherein the compaction can be carried out by at least a pair of rollers with an upper and a lower roller. It is understood that the roller device subsequent to the first pair of rollers can also have a number of further rollers or further roller pairs. The so-called short-cycle pressing lends itself to discontinuous production, wherein a lower and/or an upper pressing part are provided. The consolidation of the non-woven fabric material preferably occurs by means of (double-)belt presses with pre-heating to heat or partially fuse the fibrous material.

As a result of the application of either the continual or discontinuous method for consolidating the non-woven fabric, a rectangular panel is created with a defined edge length, width and height. The specific density of the panel is controlled by the height of the fleece material and the selected pressing force.

Irrespective of the manufacturing method, it is such that the consolidation device, i.e. either the roller device or the short-cycle pressing, carries out the consolidation or compaction of the non-woven fabric in the manner according to the invention by means of the appropriate pressure and/or appropriate temperatures. Accordingly, the respective pressing device is provided with the relevant press cylinders and/or heating devices.

To arrive at a cost-effective production of the panel according to the invention, it is provided that the panel is produced from a base panel, which is several times larger than the panel itself. The base panel is divided into a number of individual panels after its production, i.e. after the consolidation of the non-woven fabric according to the invention. Accordingly, the base panel corresponds in its dimensions to approximately a multiple of the dimensions of an individual panel.

In relation with the method according to the invention, it is also shown that it is possible to press the tongue-and-groove connection at least in some regions with the help of the pressing device. It is also possible that only a pre-contouring of the tongue-and-groove connection occurs in the pressing device. Thus, the tongue-and-groove connection can be realised from the outset when pressing the non-woven fabric. However, in principle, it is also possible that the pre-pressed fleece panels with or without locking contours are provided by means of a further pressing procedure (continual in the cycle or discontinuous) on the sides with an appropriate (supplementing) locking contour, wherein the subsequently re-pressed area is considerably harder. The pre-contouring or subsequent pressing as necessary of the tongue-and-groove connection has the significant advantage that comparatively little material of the substrate panel must be cut away for the subsequent contouring of the locking contour - if any at all. Thus the manufacturing cost for creating the locking contours is considerably reduced, which is accordingly cost-effective.

It is understood that it is also naturally possible to carry out no contouring or precontouring when consolidating the non-woven fabric, i.e. to produce a base panel in the continual or discontinuous method which is only profiled on the edges after its final construction.

Otherwise, the method according to the invention has the advantage that it is possible to bond the previously mentioned upper layer, which can also consist of multiple layers, and/or the previously mentioned lower layer, which can also consist of multiple layers, directly with the substrate layer when consolidating/pressing the non-woven fabric. With the discontinuous method, this means that first the lower layer, then the non-woven fabric being consolidated not according to the invention and thereupon the upper layer, with its individual layers where applicable, are inserted into the pressing die and then the entire bundle of layers is pressed. With the continuous method, “directly bonded” means that the respective upper or lower layer are directly fed into the first pair of rollers, which is used for the compaction or consolidation of the non-woven fabric. At the same time, it is also possible that the feeding in of the upper and/or the lower layer occurs shortly after the first pair of rollers, wherein this is possible until the continually produced base panel is separated.

In this way, decorative substrates or substances for the surface finish can be realised during the pressing procedure. The procedure is very dimensionally stable and detailed. A pressing device for the production of a panel of the aforementioned type can have an upper pressing part, a lower pressing part and a mould cavity.

On the upper pressing part and/or on the lower pressing part, at least one contouring means for moulding a tongue-and-groove connection being formed on the panel at least in some regions can be provided.

As previously mentioned, the pressing device can be a short-cycle press for the discontinuous production or a roller device with at least one pair of rollers for continual production.

For both the continual and discontinuous pressing device, at least one profiling, for example in the form of the relevant protrusions, profile recesses and/or a movable mandrel or valve protruding into the mould cavity, is provided as the contouring means. By using the aforementioned mandrel, which is movable into and out of the mould cavity in a valve-like manner, it is possible to provide an internal groove when compressing the non-woven fabric for the production of the substrate layer in this.

Furthermore, on the upper and/or lower pressing part, and irrespective of whether the pressing device is a short-cycle press ora roller device, such a contouring of the profiling can be provided, which is adapted at least substantially to the concluding groove and/or tongue design of the locking contour.

In addition, the contouring means can be provided in the form of the profiling both in the longitudinal and transverse direction on the upper and/or lower pressing part, such that it is possible with continual and discontinuous production to carry out a pre-division of the base panel into the individual panels.

Further features, advantages and possible applications of the present invention arise from the following description of exemplary embodiments on the basis of the drawing and the drawing itself. All features described and/or illustrated form the subject matter of the present invention per se or in any desired combination, independent of their summary in the claims or their back reference.

Brief description of the drawings

Fig. 1 shows a perspective schematic representation of a panel according to the invention,

Fig. 2 shows a perspective schematic representation of a furniture component panel,

Fig. 3 shows a schematic sectional view of a part of an embodiment of a panel according to the invention,

Fig. 4 shows a view according to Fig. 3 of a further embodiment of a panel according to the invention,

Fig. 5 shows a view according to Fig. 4 of a further embodiment of a panel according to the invention,

Fig. 6 shows a view according to Fig. 5 of a further embodiment of a panel according to the invention,

Fig. 7 shows a schematic representation of a part of an embodiment of a substrate panel according to the invention,

Fig. 8 shows a view according to Fig. 7 of a further embodiment of a substrate panel according to the invention,

Fig. 9 shows a schematic representation of a discontinuous pressing device before the pressing,

Fig. 10 shows a view according to Fig. 9 of the pressing device from Fig. 9 during the pressing procedure,

Fig. 11 shows a view according to Fig. 10 of the pressing device from Fig. 9 after completing the pressing procedure,

Fig. 12 shows a top view of the lower pressing part of a pressing device,

Fig. 13 shows a schematic side sectional view of a continual pressing device during the consolidation process,

Fig. 14 shows a schematic sectional view of a substrate panel made from the consolidated non-woven fabric,

Fig. 15 shows a substrate panel profiled on the edges in a schematic sectional view, Fig. 16 shows a front view of the pressing device from Fig. 13,

Fig. 17 shows a representation according to Fig. 16 of another embodiment of a continual pressing device and

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

In Fig. 1, a panel 1 is shown, which in the present case is a panel or a board for a floor covering (not shown), which is made up of a number of bonded panels 1. The panel 1 is ultimately a floor covering panel. The panel 1 has a plane substrate panel 2, on which an upper layer 3 is applied on the upper face and thereby firmly attached.

In Fig. 2, a panel 1 is shown, which is a furniture component panel. The panel 1 shown in Fig. 2 also has a substrate panel 2 and an upper layer 3. A difference between the panels 1 shown in Fig. 1 and 2 is that the floor covering panel from Fig. 1 has a locking contour on the edges, while such a contour is not provided on the edges of the furniture component panel. The edges of the panel 1 shown in Fig. 2 run at least substantially at right angles to the upper or lower side of the base panel.

The locking contours provided on the edges of the panel 1 from Fig. 1 have a protruding tongue 4 on one longitudinal side and a corresponding, complementary groove 5 on the opposite longitudinal side. Furthermore, a tongue 4 is also disposed on one short side of the rectangular panel 1, while a corresponding, complementary groove 5 is provided on the opposite short side. The tongue-and-groove connection on the longitudinal and short sides, which can also be called a ploughed-and-grooved joint, can be designed identically in principle. In the case of a click connection, they are however designed differently.

The tongue 4 and the groove 5 are provided for the formation of a so-called click connection with the consequence that the tongue 4 can be engaged into the groove 5 of a neighbouring panel during installation. In practice, the installation generally occurs through inclined positioning of the panel 1 being installed against an already installed panel 1. A preliminary engagement of the tongue 4 into the groove 5 occurs as a result. Then the panel being installed is moved down such that the interlocking occurs by means of the click connection. At the same time, a connection is created on the short sides, after the panel 1 being installed has been pushed against the already installed panel 1.

It is now provided that the panel 1, irrespective of whether it is a floor covering panel, a furniture component panel or a wall cladding or ceiling cladding panel, that the substrate panel 2 is produced from a consolidated non-woven fabric, which is needled. In the visualised embodiment, the non-woven fabric comprises at least predominantly of natural fibres. In addition, the non-woven fabric is impregnated with a binder. The weight proportion of the binder relating to the weight proportion of the non-woven fabric is thereby approx. 1:3. In the specifically shown embodiment, the consolidated non-woven fabric has a density within the range of 760 kg/m3, while it is however also possible to use substrate panels 2 with a sufficient strength, which have a considerably lower density. So in another alternative embodiment, a density within the range of 410 kg/m3 is provided. For that matter, the material of the substrate panel 2 according to the invention can be described in that the compaction degree of the unconsolidated non-woven fabric to the consolidated non-woven fabric according to the invention is within the range of 4.7.

In Fig. 3 to 6, possible embodiments of the panel 1 according to the invention are shown. In all depicted embodiment, an upper layer 3, which is formed of multiple layers in all embodiment, and a lower layer 6 are provided. Thereby the lower layer 6 is single-layered in the embodiment shown in Fig. 3 and 4, while it is formed of two layers in the embodiments shown in Fig. 5 and 6.

It is understood naturally that it is also possible in all depicted embodiments to provide a greater or smaller number of layers of the upper layer 3 or lower layer 6.

In the embodiment shown in Fig. 3, the upper layer 3 has an external layer 3a, which can be a vinyl and/or PUR and/or PP wear layer. Beneath the external layer 3a, a further layer 3b is disposed, which is a printed decorative paper. It is not shown that the further layer 3b is bond to the substrate panel 2 by means of an adhesive layer. Furthermore, an adhesive layer can also be provided between the further layer 3b and the external layer 3a.

Instead of designing the further layer 3b as a decorative paper, the further layer 3b can also be a printed vinyl substrate. The aforementioned adhesive layers (not shown) are then provided as needed.

In principle, it is also possible that the external layer 3a is formed as a corundum overlay, under which a printed decorative paper layer is located, which is impregnated, i.e. resinated. The connection to the substrate panel 2 then occurs by means of the resin of the further layer 3b.

Alternatively, it is also possible that a lacquer/corundum layer is provided on the upper face as the external layer 3a, which is applied to an underlying paper or vinyl substrate layer.

In the embodiment shown in Fig. 4, the external layer 3a is applied to a further layer 3b being formed as a protective overlay, to which a further layer 3c is connected. The layer 3b can be a protective overlay in the depicted embodiment, which is applied to a resinated, printed decorative paper layer as a further layer 3c.

In principle, it is also possible that the external layer 3a is a textured lacquer layer, while the further layer 3c can be a printable fleece, which is consolidated or else not consolidated. On the fleece layer as the further layer 3c a digital print is then applied as the further layer 3b. Instead of the printable fleece as the further layer 3c, it is also possible to provide a printed overlay layer, for example in the form of a primer.

Reference is hereby made to the fact that the individual, depicted layers are always shown with the omission of any necessary adhesive layers. The adhesive layers are also not to be understood as sublayers in the sense of the invention.

The embodiments shown in Fig. 4 and 5 correspond to the embodiments shown in Fig. 3 and 4, at least as far as the upper layer 3 is concerned. One difference exists in that the lower layer S in the embodiments of Fig. 3 and 4 is designed as a single layer, while it is formed of two layers in Fig. 5 and 6. A counter beam made of cork for example is provided as the lower layer 6 of the singlelayered embodiment. In the two-layered embodiment, a fleece layer can be provided in addition to the cork layer, which is a non-woven fabric not consolidated according to the invention. Thereby, the sequence of the arrangement of the cork layer and the non-woven fabric layer is arbitrary. In principle, a paper layer could also be provided as the counter beam separately or in connection with one or both of the aforementioned layers.

In each of Fig. 7 and 8, a part of the substrate panel 2 is shown schematically. In the embodiment shown in Fig. 7, the substrate panel 2 is two-layered and has an upper layer 2a and a lower layer 2b. In the depicted embodiment, the same non-woven fabric material is used in each case, wherein the upper layer 2a is more heavily compressed than the lower layer 2b. The lower layer 2b is thereby softer than the upper layer 2a. The embodiment shown in Fig. 7 is particularly suitable if a soft walking sensation is to be created. Thus the upper layer 2a then creates a pressure distribution over the surface of panel 1, while the layer 2b provides insulation when running/walking due to its improved compressibility and lesser hardness.

In the embodiment shown in Fig. 8, the properties of the substrate panel 2 from Fig. 7 are expanded by the properties of a further layer 2c. However, other dimensioning has been deliberately used. The layer 2c has a high compaction degree and a high thickness. This is realised thus as the layer 2e is used to form the locking contour. Accordingly, the thickness of layer 2c is greater than the maximum height of groove 5, such that the groove 5 can be designed in the layer 2c.

In Fig. 9 to 11, a part of the pressing device 7 is schematically depicted. The pressing device 7 has an upper pressing part 8 and a lower pressing part 9. Between the upper pressing part 8 and the lower pressing part 9, there is a mould cavity 10. The pressing device 7 depicted in Fig. 9 to 11 is a so-called short-cycle press, which works in a discontinuous manner. Thereby it is provided that both on the upper pressing part 8 and on the lower pressing part 9, contouring means for moulding a tongue-and-groove connection being formed on the panel 1 at least in some regions are provided. Specifically, it is in the depicted embodiment such that on the upper pressing part 8 a profiling 11 is provided, which forms the upper area or the upper contour of the tongue 4. On the lower pressing part 9, there is also a profiling 12, which forms a part of the tongue 4 and also a part of the groove 5. Furthermore, on the lower pressing part 9 there is a movable mandrel 13, the tip of which can be slid into the mould cavity 10. The tip of the mandrel 13 is profiled such that it corresponds to the form of the frontal end of the groove 5.

Furthermore, Fig. 9 to 11 depict the process flow of the discontinuous production of a substrate panel 2. Initially, a mat-shaped non-woven fabric material is inserted as the raw or basic material into the mould cavity 10 of the lower pressing part 9. The upper pressing part 8 is then moved down. Fig. 9 shows only an intermediate state. The moving down of the upper pressing part 8 occurs until both pressing parts 8, 9 lie on top of each other, as is depicted in Fig. 10. The non-woven fabric material is compacted during the pressing process. The binder found in the non-woven fabric material reacts under the influence of pressure and heat and consolidates the non-woven fabric material in the compressed state. In the depicted embodiment, there is a compaction degree of between 4:1 and 5:1. After a predefined pressing duration, the upper pressing part 8 is moved upwards, as is depicted in Fig. 11. At the same time, the mandrel 13 is retracted so far that its tip no longer or only slightly protrudes into the mould cavity 10. Then the consolidated substrate panel 2 can be removed from the pressing device 7 or the mould cavity 10.

Reference is hereby made to the fact that instead of a movable mandrel 13, a mandrel permanently protruding into the mould cavity 10 could also be provided in principle. In this case, the consolidated substrate panel must be removed at an incline from the mould cavity 10 or pressing device 7.

Furthermore, reference should be made to the fact that instead of in the embodiment shown in Fig. 9 to 11, not just one substrate panel 2 can be produced in the pressing device 7, but rather a panel 1 with an upper layer 3 and/or the lower layer 6. If both an upper layer 3 and a lower layer 6 are provided, the lower layer 6 is inserted first, onto which the not yet compressed mat made of non-woven fabric is then disposed. In turn, the upper layer 3 is then disposed onto this. The pressing of the upper and/or lower layer 3, 6 with fleece material, which then forms the substrate panel 2, occurs then during the compaction in the state shown in Fig. 10.

Furthermore, reference should be made to the fact that it is also possible in principle to produce instead of one single panel 1 or substrate panel 2 a base panel, which is split after consolidation of the non-woven fabric into a number of individual panels 1 or substrate panels 2.

In Fig. 12, a top view is shown of a lower pressing part 9 of a pressing device 7, with which a base panel can be produced with 16 individual panels 1. The lower pressing part 9 has a series of contouring means in the form of profilings 14, which are longitudinal and transverse projections, which ultimately predefine the rectangular formed panel 1. On the upper face, the profilings are adjusted at least in some regions to the form of the locking contour, i.e. to the tongue 4 and/or the groove 5 of the panel 1. An upper pressing part (not shown) corresponds to the lower pressing part 9 shown in Fig. 12, said upper pressing part corresponding in terms of division to the division of the lower pressing part 9 shown in Fig. 12, wherein the profilings provided there do not necessarily correspond to the profilings of the opposite pressing part, but are adjusted to the upper face profiling of tongue 4.

Furthermore, it is understood that the depicted embodiment of the lower pressing part 9 is only an example. In principle, the lower pressing part 9 can have any number and form of compartments for panels 1.

In Fig. 13, a continual pressing device 7 is schematically depicted. This has a roller as the upper and lower pressing part 8, 9, which each have in this case a profiling 14. However, reference should be made to the fact that the profiling 14, which depicts the form of a circumferential projection with pre-contouring as required in adjustment to the profile of the tongue-and-groove connection, can in principle also be omitted, such that only smooth, cylindrical rollers are used.

From Fig. 13, the type of consolidation is also shown schematically. Into the pressing device 7 and/or the rollers is fed a non-woven fabric material being impregnated with a binder or having thermoplastic fibres, said non-woven fabric material is compacted for consolidation. A consolidation occurs hereby under a predefined pressure and a predefined temperature, wherein a compaction degree of between 4:1 and 5:1 is achieved.

In Fig. 14, the substrate panel 2 produced according to the method in Fig. 13 is schematically depicted, which has been separated from the produced material line after production by the pressing device 7. It is understood that in the method according to Fig. 13 individual substrate panel 2 and also base panels, which are then split into individual panels 1, can be produced. Furthermore, it is also possible with the continual method to produce not just the substrate panels 2 by means of the pressing device 7 designed as a roller device, but also the panel 1 as such. Hereby, the upper layer 3 and/or the lower layer 6 then run directly to the pair of rollers 8, 9 or else the running-in of the individual layers 3, 6 occurs after the pair of rollers and before partitioning of the base panel / panel 1 / substrate panel 2.

While the substrate panel 2 depicted in Fig. 14 can in principle be used as a furniture component, which is then provided on the upper face with the upper layer 3 and on the underside with the lower layer 6 and can also be provided with corresponding layers on the edges, a substrate panel 2 is depicted in Fig. 15, which is processed on the edges and on which appropriate locking contours are provided by means of a tongue 4 and groove 5. Then the upper layer 3 can be provided on the top side of the substrate panel 2 and the lower layer 6 can be provided on the underside. In the embodiment depicted in Fig. 14, which is particularly suitable as a furniture component panel, it can be provided that a lacquer coating is provided as a layer on the upper side and underside and on the edges.

In Fig. 16, a front view of the pressing device 7 from Fig. 13 is depicted. The two outer profilings 14 and the interjacent central profiling 14 are recognisable on the rollers. Though this is not shown in detail, the profilings 14 are not designed on their ends as V-shaped, but correspond at least in some regions to the contouring or the profile of the tongue-and-groove connection on the upper side and underside of panel 1.

The embodiment according to Fig. 17 differs from that in Fig. 16 in that on the pressing parts 8, 9 designed as rollers additional transverse profilings 15 are provided as well as the profilings 14 running longitudinally in the rotational direction, said transverse profilings being ultimately defined along with the panel 1 or substrate panels 2 of a base panel being produced. The transverse profilings 15 are also adjusted on their top side at least in some regions to the profile or the contour of the locking contour of panel 1.

Fig. 18 shows a transverse view of the pressing device 7 from Fig. 17.

List of reference signs: 1 Panel 2 Substrate panel 2a Upper layer 2b Additional layer 2c Additional layer 3 Upper layer 3a Outer layer 3b Additional layer 3c Additional layer 4 Tongue 5 Groove 6 Lower layer 7 Pressing device 8 Upper pressing part 9 Lower pressing part 10 Mould cavity 11 Profiling 12 Profiling 13 Mandrel 14 Profiling 15 Profiling

Claims (9)

Plate for floor, wall or ceiling or for a furniture component and method for making such a plate A plate (1) for a floor, wall or ceiling covering or for a furniture component, preferably floor covering, wall covering or ceiling covering or furniture component plate, with a flat support plate (2) and an upper layer (3) applied to it. the carrier plate (2), characterized in that the carrier plate (2) is made by curing a needle fiber cloth or that the carrier plate (2) is provided at least with a support layer of a hardened needle fiber cloth, the density of the cured fiber cloth being between 400 kg / m3 and 1000 kg / m3 and the compaction rate of the uncured fiber cloth relative to the cured fiber cloth is between 10: 1 and 2: 1 and a lower layer (6) is provided which is located on the underside of the support layer. Plate according to claim 1, characterized in that the nonwoven fabric is made of natural polymer fibers and / or synthetic polymer fibers and / or recycled fibers and that the nonwoven fabric is mechanically or thermally cured. Plate according to claim 1 or 2, characterized in that the nonwoven fabric is wetted with adhesives and / or is provided with thermoplastic polymer fibers and that, preferably, the support plate (2) has a greater proportion of nonwoven material and a smaller proportion of adhesive and / or thermoplastic polymer fibers. Plate according to one of the preceding claims, characterized in that the material of the carrier plate (2) has a density of between 400 kg / m3 and 900 kg / m3, and / or that the surface weight of the carrier plate (2) per unit weight is 2. mm thickness is between 500 and 1500 g / m2. Plate according to one of the preceding claims, characterized in that the supporting plate (2) on the edge side has a not-fer contour and that the supporting plate (2) in the area of the not-fer contour is more strongly cured than outside the not-fer area of the contour. Plate according to one of the preceding claims, characterized in that the support plate (2) is formed in several layers and that at least two layers of the support plate (2) have a different degree of compaction and / or curing. A method of manufacturing a plate (1) according to any of the preceding claims for a floor, wall or ceiling covering or for a furniture component, preferably floor covering, wall covering or ceiling covering or furniture component plate, wherein the plate (1) contains a plan carrier plate (2) and an upper layer (3) applied to the carrier plate (2), characterized in that the carrier plate (2) is made of a needle fiber cloth by curing by means of a pressing device (7), the density of the cured fiber cloth is between 400 kg / m3 and 1000 kg / m3, and the compaction rate of the non-cured nonwovens relative to the hardened nonwovens is between 10: 1 and 2: 1. Method according to claim 7, characterized in that a notfer connection is at least regionally pressed in a pressing device (7) and / or that the plate (1) or the supporting plate (2) is profiled on the edge side for producing the notch. s contour. Method according to claim 7 or 8, characterized in that the support layer (2) is, when curing the nonwoven fabric, connected to an upper layer (3) and / or a lower layer (6).