EP1085978A1 - Method for producing a floor covering with natural or synthetic wood facing and resulting product - Google Patents

Method for producing a floor covering with natural or synthetic wood facing and resulting product

Info

Publication number
EP1085978A1
EP1085978A1 EP99917840A EP99917840A EP1085978A1 EP 1085978 A1 EP1085978 A1 EP 1085978A1 EP 99917840 A EP99917840 A EP 99917840A EP 99917840 A EP99917840 A EP 99917840A EP 1085978 A1 EP1085978 A1 EP 1085978A1
Authority
EP
European Patent Office
Prior art keywords
floor covering
manufacturing
sheet
covering according
facing
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP99917840A
Other languages
German (de)
French (fr)
Inventor
Ludovic Delcroix
Albert Roussel
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Tarkett Sommer SA
Original Assignee
Tarkett Sommer SA
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Tarkett Sommer SA filed Critical Tarkett Sommer SA
Priority to EP99917840A priority Critical patent/EP1085978A1/en
Publication of EP1085978A1 publication Critical patent/EP1085978A1/en
Withdrawn legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/12—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
    • B27N—MANUFACTURE BY DRY PROCESSES OF ARTICLES, WITH OR WITHOUT ORGANIC BINDING AGENTS, MADE FROM PARTICLES OR FIBRES CONSISTING OF WOOD OR OTHER LIGNOCELLULOSIC OR LIKE ORGANIC MATERIAL
    • B27N3/00—Manufacture of substantially flat articles, e.g. boards, from particles or fibres
    • B27N3/06—Making particle boards or fibreboards, with preformed covering layers, the particles or fibres being compressed with the layers to a board in one single pressing operation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B21/00—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board
    • B32B21/04—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B21/08—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin

Definitions

  • the present invention relates to a method for producing a floor covering which comprises a natural or synthetic wood facing which is essentially in the form of a panel or a strip.
  • This process has several advantages, among which the reduction in the number of manufacturing operations, the control of the composition and precise characteristics of the panel, the homogeneity of the product obtained as well as the possibility of recycling the waste.
  • modifying the characteristics of the panel by varying the rate of glue and possibly its nature.
  • the density of the panel as well as the composition of the core by incorporating particles less sensitive to water than cellulosic plant materials.
  • coatings with improved humidity behavior can be obtained, this is still insufficient for certain applications.
  • the products obtained do not have sufficient impermeability. In fact, moisture accumulates on the surface, which will create a humidity gradient that unbalances the entire product. This essentially results in "curling" and deformation of the edges of the blades.
  • Document GB-A-2 238 015 describes a panel made from a non-flexible cellulosic substrate 3
  • the joining is carried out in a step where the substrate is placed on a backward grid and which has a pressure of the order of 15 kg / cm ⁇ for temperatures between 150 and 200 ° C. According to this document, it is essential to work under such low pressures since it is important to be able to cause proper degassing of the panel.
  • the present invention aims to provide a laminate essentially produced according to the method described in the previous application O96 / 04114 which exhibits a further improved behavior of resistance to humidity.
  • the present invention aims in particular to avoid any phenomenon of curling or deformation of the edges for a panel produced according to a method as described in the previous application O96 / 04114.
  • the present invention also aims to propose a method allowing the production of a laminate as described in the previous application O96 / 04114 but which does not present degassing problems.
  • the present invention aims to propose solving the problems of the state of the art, in particular in the case of use in particularly humid premises.
  • the solution consists in adding a protective sheet of thermoplastic type between the decorative facing and the core of the product in order to avoid that 4
  • thermoplastic sheet could be interposed between the different layers of the panel which are made from essentially thermosetting materials without causing any particular tension between these different layers and despite the severe conditions of agglomeration.
  • a first object of the present invention therefore lies in the fact of proposing a method of manufacturing a floor covering with natural or even synthetic wood facing, in which a backing is assembled in a single step acting as counter facing. balancing, an intermediate layer intended to constitute the core of the coating and which is essentially composed of a mixture of fine organic particles and of a non-crosslinked thermosetting powder adhesive, of a sheet of thermoplastic material, of a decorative facing and a sheet intended to constitute the wear layer made of a thermosetting material, the whole being kept in press under conditions of high temperature and pressure in order to cause the crosslinking of the adhesive.
  • high temperature and high pressure means a temperature between 120 and 200 ° C for a pressure between 30 and 150 kg / cm ⁇ .
  • the intermediate layer is produced, in a previous step, in the form of a "cake" which is intended to constitute the core. of the floor covering by mixing the fine organic particles and the thermosetting adhesive and subjecting this mixture to a 5
  • thermoplastic sheet based on polyolefin, and this for essentially ecological reasons (absence of chlorine) but also economic.
  • the viscosity of the mixture intended to make the thermoplastic sheet must be adapted so as to avoid any creep, and therefore the tearing of the decorative facing possibly consisting of a paper during assembly under high pressure and high temperature.
  • thermoplastic sheet between the core of the coating and the decorative facing makes it possible to obtain an improvement in the abrasion resistance.
  • This is in fact due to the fact that the surface will no longer be deformed by the roughness of the intermediate layer due to the presence of organic particles which can be relatively coarse.
  • This also leads to the result that it is possible to envisage using even coarser particles for the manufacture of the floor covering or panel, with the consequence that the recycled waste may also be coarser.
  • the balancing counter-facing may be lighter because the tensions generated at the surface are lower. 6
  • the present invention it is possible to use as decorative facing a printed paper impregnated or not with melamine, and this without fear of the appearance of spots of glue in the decor.
  • the properties of the final product obtained by means of the method described in document WO96 / 04114 are preserved; in particular the resistance to shocks, to cigarette burns and to stains is fully maintained.
  • the present invention relates to a method of manufacturing a floor covering which, within the same product, makes it possible to combine thermoplastic materials and thermosetting materials.
  • Thermoplastic materials exhibit elongation when the temperature increases, and tend to shrink when the temperature decreases.
  • thermosetting products with thermoplastic products during a single manufacturing step.
  • a first object of the invention consists in proposing a method which, in the same step, makes it possible to assemble a backing 1 acting as a counter-facing for balancing, an intermediate layer 10 intended to constitute the core of the coating and which is essentially composed of a mixture of fine organic particles and thermosetting adhesive, essentially non-crosslinked, a sheet of thermoplastic material 20, a decorative facing 3 and a sheet 4 intended to constitute the wear layer made of a thermosetting material.
  • thermoplastic sheet 20 is produced by conventional techniques per se, such as calendering or extrusion.
  • a conventional polyolefin composition is given below by way of example.
  • the mixture is calendered at a temperature between 160 and 180 ° C, so as to obtain a sheet which is extracted from the fourth cylinder at a temperature close to 100 ° C with a thickness of the order of 300 ⁇ m.
  • the sheet is then cooled and cut to the format of the panel which must allow the flooring to be produced.
  • the core 10 of the coating is prepared based on a mixture of sawdust, crushed waste and a powdered thermosetting adhesive.
  • This glue is preferably a phenolic resin.
  • various other additives can also be incorporated.
  • This mixture is homogeneously sprinkled on a conveyor belt and is preheated to a temperature between 80 and 100 ° C, degassed at 80 ° C and then subjected to a pressure of 60 to 80 kg / cm 2 at a temperature of 80 ° C for a period of 30 seconds.
  • the coating manufacturing process consists of successively depositing on a transport sheet a balancing counter-facing (reverse side), the pre-agglomerated cake described above having a weight of 6.6 kg / m 2 , a polyolefin sheet such as described above, a decorative printed paper and a wear layer in the form of a melamine overlay.
  • the assembly is covered by a graining sheet to give it a surface appearance if necessary.
  • the assembly is subjected to a pressure of 60 to 120 kg / m 2 at a temperature of 160 ° C for 4 minutes.
  • the agglomerated product is then transported in a cold press, where it is cooled to a temperature of 33 ° C under low pressure for 4 minutes.
  • the panel is then signed and cut into strips, and stabilized for a few days before machining the groove and tongue edges for assembly.
  • a sheet of sealing polyolefin can be interposed between the reverse side and the pre-agglomerated cake.
  • thermoplastic sheet for which a thermoplastic sheet is prepared essentially as described above, but with the following composition:
  • a cake is also produced intended to produce the core of the coating as described above.
  • a balancing counter-facing is successively deposited on a transport sheet which may possibly consist of a wood veneer sheet, the pre-agglomerated cake described above having a weight of 6.6 kg / m 2 , a calendered polyolefin sheet as described above, a wooden veneer sheet with a thickness of 0.6 mm and finally a wear layer in the form of a melamine overlay.
  • the assembly is subjected to the same conditions as mentioned above.

Abstract

The invention concerns a method for making a floor covering in the form of panels, characterised in that it consists in assembling in one step a back (1) acting as balancing rear face, an intermediate layer (10) for forming the flooring core and which is substantially made of a mixture of fine organic particles and thermosetting and non-cured powder glue, a thermoplastic sheet (20), a decorative facing (3) and a sheet (4) designed to constitute the top surface made of a thermosetting material, the whole assembly being maintained at a temperature ranging from 120 to 200 DEG C for a pressure ranging between 30 and 150 kg/cm<2>, so as to cause the glue to set.

Description

PROCEDE DE REALISATION D'UN REVETEMENT DE SOL A PAREMENT EN BOIS NATUREL OU SYNTHETIQUE ET PRODUIT OBTENUPROCESS FOR PRODUCING A FLOORING WITH NATURAL OR SYNTHETIC WOOD SIDING AND PRODUCT OBTAINED
Objet de l'inventionSubject of the invention
La présente invention se rapporte à un procédé de réalisation d'un revêtement de sol qui comporte un parement en bois naturel ou synthétique se présentant essentiellement sous la forme d'un panneau ou d'une lame.The present invention relates to a method for producing a floor covering which comprises a natural or synthetic wood facing which is essentially in the form of a panel or a strip.
La présente invention se rapporte également au revêtement de sol obtenu par ledit procédé, comprenant soit un parement de bois naturel, soit un parement synthétique .The present invention also relates to the floor covering obtained by said process, comprising either a natural wood facing, or a synthetic facing.
Arrière-plan technologique à la base de l'inventionTechnological background underlying the invention
Dans la publication WO96/04114, on a décrit un procédé de fabrication de revêtements de sol à parement en bois naturel ou synthétique, dans lequel on assemble en une seule étape un envers faisant fonction de contre- parement d'équilibrage, une couche intermédiaire destinée à constituer l'âme du revêtement, un parement décoratif et éventuellement une feuille destinée à constituer la couche d'usure, le tout étant maintenu sous presse à une haute température et à haute pression en vue de provoquer la réticulation de la colle présente dans la couche intermédiaire .In publication WO96 / 04114, a process has been described for manufacturing floor coverings with natural or synthetic wood siding, in which a backing serving as a counterbalancing counter is assembled in a single step, an intermediate layer intended to constitute the core of the coating, a decorative facing and possibly a sheet intended to constitute the wear layer, the whole being kept in press at a high temperature and at high pressure in order to cause the crosslinking of the glue present in the middle layer.
Eventuellement, on peut prévoir de réaliser dans une étape préalable un composé pré-aggloméré qui va 2Optionally, provision can be made in a preliminary step for a pre-agglomerated compound which will 2
servir à réaliser l'âme du panneau et que l'on appelle également habituellement "gâteau", obtenu en tassant légèrement un mélange sec de particules fines organiques et de colle en poudre non réticulée que l'on soumet à un traitement thermique à basse température sous pression. Ce traitement permet d'obtenir un composé cohérent, que l'on peut aisément manipuler pour permettre la réalisation du panneau final constituant le revêtement de sol.serve to make the core of the panel and also usually called "cake", obtained by compacting a dry mixture of organic fine particles and non-crosslinked powder glue which is subjected to a heat treatment at low temperature under pressure. This treatment makes it possible to obtain a coherent compound, which can easily be manipulated to allow the production of the final panel constituting the floor covering.
Ce procédé présente plusieurs avantages, parmi lesquels la réduction du nombre d'opérations de fabrication, le contrôle de la composition et des caractéristiques précises du panneau, l'homogénéité du produit obtenu ainsi que la possibilité de recycler les déchets. Pour un type particulier d'application, qui se rapporte à l'utilisation dans les locaux humides tels qu'une salle de bain ou une cuisine, on peut envisager de modifier les caractéristiques du panneau en faisant varier le taux de colle et éventuellement sa nature, la densité du panneau ainsi que la composition de l'âme par incorporation de particules moins sensibles à l'eau que les matières végétales cellulosiques. Néanmoins, bien que l'on puisse obtenir des revêtements présentant un comportement amélioré à l'humidité, celui-ci reste encore insuffisant pour certaines applications. En particulier dans le cas d'utilisation de parements à base de papier mélaminé, on observe que les produits obtenus ne présentent pas une imperméabilité suffisante. En effet, l'humidité s'accumule en surface, ce qui créera un gradient d'humidité déséquilibrant tout le produit. Cela se traduit essentiellement par un "tuilage" et une déformation des bords des lames.This process has several advantages, among which the reduction in the number of manufacturing operations, the control of the composition and precise characteristics of the panel, the homogeneity of the product obtained as well as the possibility of recycling the waste. For a particular type of application, which relates to use in damp rooms such as a bathroom or a kitchen, one can consider modifying the characteristics of the panel by varying the rate of glue and possibly its nature. , the density of the panel as well as the composition of the core by incorporating particles less sensitive to water than cellulosic plant materials. However, although coatings with improved humidity behavior can be obtained, this is still insufficient for certain applications. In particular in the case of the use of facings based on melamine paper, it is observed that the products obtained do not have sufficient impermeability. In fact, moisture accumulates on the surface, which will create a humidity gradient that unbalances the entire product. This essentially results in "curling" and deformation of the edges of the blades.
Le document GB-A-2 238 015 décrit un panneau constitué à partir d'un substrat cellulosique non flexible 3Document GB-A-2 238 015 describes a panel made from a non-flexible cellulosic substrate 3
et présentant une surface non égalisée sur laquelle on dispose une couche de polyoléfine faisant fonction d'une colle et sur laquelle va adhérer un papier kraft ou verni. La solidarisation est réalisée en une étape où l'on dispose le substrat sur une grille en envers et qui présente une pression de l'ordre de 15 kg/cm^ pour des températures comprises entre 150 et 200 °C . Selon ce document, il est indispensable de travailler sous des pressions aussi faibles étant donné qu'il est important de pouvoir provoquer un dégazage correct du panneau.and having an uneven surface on which there is a polyolefin layer acting as an adhesive and on which will adhere a kraft or varnished paper. The joining is carried out in a step where the substrate is placed on a backward grid and which has a pressure of the order of 15 kg / cm ^ for temperatures between 150 and 200 ° C. According to this document, it is essential to work under such low pressures since it is important to be able to cause proper degassing of the panel.
Buts de l'inventionAims of the invention
La présente invention vise à proposer un stratifié essentiellement réalisé selon le procédé décrit dans la demande antérieure O96/04114 qui présente un comportement encore amélioré de résistance à l'humidité.The present invention aims to provide a laminate essentially produced according to the method described in the previous application O96 / 04114 which exhibits a further improved behavior of resistance to humidity.
La présente invention vise en particulier à éviter tout phénomène de tuilage ou de déformation des bords pour un panneau réalisé selon un procédé tel que décrit dans la demande antérieure O96/04114.The present invention aims in particular to avoid any phenomenon of curling or deformation of the edges for a panel produced according to a method as described in the previous application O96 / 04114.
La présente invention vise également à proposer un procédé permettant la réalisation d'un stratifié tel que décrit dans la demande antérieure O96/04114 mais qui ne présente pas de problèmes de dégazage.The present invention also aims to propose a method allowing the production of a laminate as described in the previous application O96 / 04114 but which does not present degassing problems.
Principaux éléments caractéristiques de 1 ' inventionMain characteristic features of the invention
La présente invention vise à proposer de résoudre les problèmes de l'état de la technique, en particulier dans le cas d'une utilisation dans des locaux particulièrement humides. La solution consiste à ajouter une feuille de protection de type thermoplastique entre le parement décoratif et l'âme du produit afin d'éviter que 4The present invention aims to propose solving the problems of the state of the art, in particular in the case of use in particularly humid premises. The solution consists in adding a protective sheet of thermoplastic type between the decorative facing and the core of the product in order to avoid that 4
l'humidité provenant de l'intérieur du produit n'atteigne la surface du panneau.moisture from inside the product does not reach the surface of the panel.
On a observé que, de manière surprenante, on pouvait intercaler une feuille thermoplastique entre les différentes strates du panneau qui sont réalisées à base de matières essentiellement thermodurcissables sans provoquer de tension particulière entre ces différentes strates et malgré les conditions sévères d'agglomération.It has been observed that, surprisingly, a thermoplastic sheet could be interposed between the different layers of the panel which are made from essentially thermosetting materials without causing any particular tension between these different layers and despite the severe conditions of agglomeration.
Un premier objet de la présente invention réside donc dans le fait de proposer un procédé de fabrication d'un revêtement de sol à parement en bois naturel ou même synthétique, dans lequel on assemble en une seule étape un envers faisant fonction de contre-parement d'équilibrage, une couche intermédiaire destinée à constituer l'âme du revêtement et qui est essentiellement composée d'un mélange de fines particules organiques et d'une colle en poudre thermodurcissable et non réticulée, d'une feuille en matériau thermoplastique, d'un parement décoratif et d'une feuille destinée à constituer la couche d'usure réalisée en un matériau thermodurcissable, le tout étant maintenu sous presse dans des conditions de température et de pression élevées en vue de provoquer la réticulation de la colle.A first object of the present invention therefore lies in the fact of proposing a method of manufacturing a floor covering with natural or even synthetic wood facing, in which a backing is assembled in a single step acting as counter facing. balancing, an intermediate layer intended to constitute the core of the coating and which is essentially composed of a mixture of fine organic particles and of a non-crosslinked thermosetting powder adhesive, of a sheet of thermoplastic material, of a decorative facing and a sheet intended to constitute the wear layer made of a thermosetting material, the whole being kept in press under conditions of high temperature and pressure in order to cause the crosslinking of the adhesive.
Par "haute température et haute pression", on entend une température comprise entre 120 et 200 °C pour une pression comprise entre 30 et 150 kg/cm^ .By "high temperature and high pressure" means a temperature between 120 and 200 ° C for a pressure between 30 and 150 kg / cm ^.
Eventuellement, selon une forme d'exécution encore préférée et déjà mentionnée dans la publication antérieure WO96/04114, on réalise, lors d'une étape précédente, la couche intermédiaire sous forme d'un "gâteau" qui est destiné à constituer l'âme du revêtement de sol en mélangeant les fines particules organiques et la colle thermodurcissable et en soumettant ce mélange à un 5Optionally, according to a more preferred embodiment and already mentioned in the previous publication WO96 / 04114, the intermediate layer is produced, in a previous step, in the form of a "cake" which is intended to constitute the core. of the floor covering by mixing the fine organic particles and the thermosetting adhesive and subjecting this mixture to a 5
traitement à relativement basse température, c'est-à-dire entre 50 et 100 °C pour une pression comprise entre 30 et 100 kg/cm2.treatment at relatively low temperature, that is to say between 50 and 100 ° C for a pressure between 30 and 100 kg / cm 2 .
Selon une forme d'exécution encore préférée, on propose d'incorporer une feuille thermoplastique à base de polyoléfine, et ceci pour des raisons essentiellement écologiques (absence de chlore) mais également économiques.According to a more preferred embodiment, it is proposed to incorporate a thermoplastic sheet based on polyolefin, and this for essentially ecological reasons (absence of chlorine) but also economic.
Selon une autre forme d'exécution, on peut envisager d'utiliser une feuille à base de polyéthylène et d'ionomères.According to another embodiment, it is possible to envisage using a sheet based on polyethylene and ionomers.
La viscosité du mélange destiné à réaliser la feuille thermoplastique devra être adaptée de manière à éviter tout fluage, et donc le déchirement du parement décoratif constitué éventuellement par un papier lors de l'assemblage sous haute pression et haute température.The viscosity of the mixture intended to make the thermoplastic sheet must be adapted so as to avoid any creep, and therefore the tearing of the decorative facing possibly consisting of a paper during assembly under high pressure and high temperature.
On observe en outre de manière particulièrement avantageuse que le fait de disposer une feuille thermoplastique entre l'âme du revêtement et la parement décoratif permet d'obtenir un amélioration de la résistance à l'abrasion. Ceci est en effet dû au fait que la surface ne sera plus déformée par les aspérités de la couche intermédiaire dues à la présence de particules organiques qui peuvent être relativement grossières. Ceci conduit également au résultat que l'on peut envisager d'utiliser des particules encore plus grossières pour la fabrication du revêtement de sol ou panneau, avec pour conséquence que les déchets recyclés pourront également être plus grossiers.It is also observed in a particularly advantageous manner that the fact of having a thermoplastic sheet between the core of the coating and the decorative facing makes it possible to obtain an improvement in the abrasion resistance. This is in fact due to the fact that the surface will no longer be deformed by the roughness of the intermediate layer due to the presence of organic particles which can be relatively coarse. This also leads to the result that it is possible to envisage using even coarser particles for the manufacture of the floor covering or panel, with the consequence that the recycled waste may also be coarser.
On observe également de manière avantageuse que le contre-parement d'équilibrage pourra être plus léger du fait que les tensions générées en surface sont plus faibles . 6It is also advantageously observed that the balancing counter-facing may be lighter because the tensions generated at the surface are lower. 6
Selon la présente invention, on pourra utiliser comme parement décoratif un papier imprimé imprégné ou non de mélamine, et ceci sans crainte de l'apparition de taches de colle dans le décor. En outre, on observe que les propriétés du produit final obtenues grâce au procédé décrit dans le document WO96/04114 sont préservées; en particulier la résistance aux chocs, à la brûlure de cigarette et aux taches est totalement maintenue. On peut également envisager d'utiliser une feuille thermoplastique sur l'envers du produit en vue de l'équilibrage et de 1 ' étanchéité de celui-ci.According to the present invention, it is possible to use as decorative facing a printed paper impregnated or not with melamine, and this without fear of the appearance of spots of glue in the decor. In addition, it is observed that the properties of the final product obtained by means of the method described in document WO96 / 04114 are preserved; in particular the resistance to shocks, to cigarette burns and to stains is fully maintained. One can also consider using a thermoplastic sheet on the back of the product for the purpose of balancing and sealing it.
Brève description de la figure La présente invention sera décrite plus en détail à l'aide de l'exemple d'exécution préféré se référant à la figure unique annexée, qui représente un revêtement de sol réalisé selon le procédé de la présente invention.BRIEF DESCRIPTION OF THE FIGURE The present invention will be described in more detail with the aid of the preferred embodiment with reference to the attached single figure, which represents a floor covering produced according to the method of the present invention.
Description détaillée de plusieurs formes d'exécution préférées de l'inventionDetailed description of several preferred embodiments of the invention
La présente invention se rapporte à un procédé de fabrication d'un revêtement de sol qui au sein d'un même produit permet de combiner les matières thermoplastiques et les matières thermodurcissables .The present invention relates to a method of manufacturing a floor covering which, within the same product, makes it possible to combine thermoplastic materials and thermosetting materials.
On sait depuis longtemps que les comportements de ces deux types de matériaux sont très différents, et parfois même inconciliables. Les matériaux thermoplastiques présentent un allongement lorsque la température augmente, et ont tendance à se rétrécir lorsque celle-ci diminue. Les matériaux thermodurcissables présentent un durcissement plus élevé de la matière lorsque la température augmente, et de ce fait, se rétractent lors de la réticulation.It has long been known that the behaviors of these two types of materials are very different, and sometimes even irreconcilable. Thermoplastic materials exhibit elongation when the temperature increases, and tend to shrink when the temperature decreases. Thermosetting materials exhibit higher material hardening when the temperature increases, and as a result, shrink during crosslinking.
Cependant, on a observé que de manière particulièrement surprenante, on pouvait parvenir à réaliser des produits présentant une stabilité dimensionnelle suffisante en combinant des produits thermodurcissables à des produits thermoplastiques lors d'une seule et même étape de fabrication.However, it has been observed that, in a particularly surprising manner, it was possible to achieve products having sufficient dimensional stability by combining thermosetting products with thermoplastic products during a single manufacturing step.
Un premier objet de l'invention consiste à proposer un procédé qui, dans une même étape, permet d'assembler un envers 1 faisant fonction de contre-parement d'équilibrage, une couche intermédiaire 10 destinée à constituer l'âme du revêtement et qui est essentiellement composée d'un mélange de fines particules organiques et de colle thermodurcissable, essentiellement non réticulée, une feuille en matériau thermoplastique 20, un parement décoratif 3 et une feuille 4 destinée à constituer la couche d'usure réalisée en un matériau thermodurcissable.A first object of the invention consists in proposing a method which, in the same step, makes it possible to assemble a backing 1 acting as a counter-facing for balancing, an intermediate layer 10 intended to constitute the core of the coating and which is essentially composed of a mixture of fine organic particles and thermosetting adhesive, essentially non-crosslinked, a sheet of thermoplastic material 20, a decorative facing 3 and a sheet 4 intended to constitute the wear layer made of a thermosetting material.
On réalise la feuille thermoplastique 20 par des techniques classiques en soi, telles que le calandrage ou l'extrusion. Une composition classique de polyoléfine est reprise ci-dessous à titre d'exemple.The thermoplastic sheet 20 is produced by conventional techniques per se, such as calendering or extrusion. A conventional polyolefin composition is given below by way of example.
PE 60PE 60
Ionomère copoly ère 30Ionomer copoly era 30
Ionomère terpolymère 10Ionomer terpolymer 10
Craie 150Chalk 150
Huile 3Oil 3
Antioxydant 0.5Antioxidant 0.5
Stéarine 0.50.5 stearin
Pigment Selon la couleur Pigment According to color
Ces matières sont mélangées et fondues à l'aide de plusieurs mélangeurs successifs à une température 8These materials are mixed and melted using several successive mixers at a temperature 8
proche de 180 °C . Le mélange est ensuite légèrement refroidi à la sortie jusqu'à une température d'environclose to 180 ° C. The mixture is then slightly cooled at the outlet to a temperature of approximately
175 °C pour alimenter une calandre à quatre cylindres.175 ° C to feed a four-cylinder radiator grille.
Le mélange est calandre à une température comprise entre 160 et 180 °C, de façon à obtenir une feuille qui est extraite du quatrième cylindre à une température proche de 100 °C en présentant une épaisseur de l'ordre de 300 μm.The mixture is calendered at a temperature between 160 and 180 ° C, so as to obtain a sheet which is extracted from the fourth cylinder at a temperature close to 100 ° C with a thickness of the order of 300 μm.
La feuille est ensuite refroidie et découpée au format du panneau qui doit permettre de réaliser le revêtement de sol .The sheet is then cooled and cut to the format of the panel which must allow the flooring to be produced.
Ensuite, on effectue la préparation de l'âme 10 du revêtement à base d'un mélange de sciure de bois, de déchets broyés et d'une colle thermodurcissable en poudre. Cette colle est de préférence une résine phénolique. Eventuellement, divers autres additifs peuvent y être également incorporés.Next, the core 10 of the coating is prepared based on a mixture of sawdust, crushed waste and a powdered thermosetting adhesive. This glue is preferably a phenolic resin. Optionally, various other additives can also be incorporated.
Ce mélange est saupoudré de manière homogène sur un tapis transporteur et est préchauffé à une température comprise entre 80 et 100 °C, dégazé à 80 °C et puis soumis à une pression de 60 à 80 kg/cm2 à une température de 80 °C pendant une durée de 30 secondes.This mixture is homogeneously sprinkled on a conveyor belt and is preheated to a temperature between 80 and 100 ° C, degassed at 80 ° C and then subjected to a pressure of 60 to 80 kg / cm 2 at a temperature of 80 ° C for a period of 30 seconds.
Le panneau obtenu, qui est appelé égalementThe resulting panel, which is also called
"gâteau", est ensuite découpé au format désiré du panneau et est stocké sur palette. Les bords sont recyclés directement ."cake", is then cut to the desired format of the panel and is stored on a pallet. The edges are recycled directly.
Le fait de réaliser une étape préalable en vue d'obtenir le gâteau permet de pouvoir ensuite réaliser le procédé de fabrication tel que décrit précédemment sans devoir se soucier d'un dégazage qui pourrait se produire lors de ce procédé. En particulier, aucune précaution particulière ne devra être prise. Le procédé de fabrication du revêtement consiste à déposer successivement sur une tôle de transport un contre-parement d'équilibrage (envers), le gâteau pré-aggloméré décrit précédemment présentant un poids de 6,6 kg/m2, une feuille de polyoléfine telle que décrite ci- dessus, un papier imprimé décoratif et une couche d'usure se présentant sous forme d'overlay mélamine. Eventuellement, l'ensemble est recouvert par une tôle de grainage pour lui donner si nécessaire un aspect de surface. L'ensemble est soumis à une pression de 60 à 120 kg/m2 à une température de 160 °C pendant 4 minutes.The fact of carrying out a preliminary step in order to obtain the cake makes it possible then to be able to carry out the manufacturing process as described above without having to worry about degassing which could occur during this process. In particular, no special precautions should be taken. The coating manufacturing process consists of successively depositing on a transport sheet a balancing counter-facing (reverse side), the pre-agglomerated cake described above having a weight of 6.6 kg / m 2 , a polyolefin sheet such as described above, a decorative printed paper and a wear layer in the form of a melamine overlay. Optionally, the assembly is covered by a graining sheet to give it a surface appearance if necessary. The assembly is subjected to a pressure of 60 to 120 kg / m 2 at a temperature of 160 ° C for 4 minutes.
Le produit aggloméré est ensuite transporté sous presse froide, où il est refroidi jusqu'à une température de 33 °C sous faible pression pendant 4 minutes .The agglomerated product is then transported in a cold press, where it is cooled to a temperature of 33 ° C under low pressure for 4 minutes.
Le panneau est ensuite émargé et découpé en lames, et stabilisé pendant quelques jours avant usinage des chants en rainure et languette pour l'assemblage.The panel is then signed and cut into strips, and stabilized for a few days before machining the groove and tongue edges for assembly.
Eventuellement, on peut intercaler une feuille de polyoléfine d'étanchéité entre l'envers et le gâteau pré-aggloméré .Optionally, a sheet of sealing polyolefin can be interposed between the reverse side and the pre-agglomerated cake.
Selon une seconde forme d'exécution préférée, on peut envisager de réaliser un panneau à revêtement bois naturel, pour lequel on prépare une feuille thermoplastique essentiellement comme décrit ci -dessus, mais avec la composition suivante :According to a second preferred embodiment, it is possible to envisage making a panel with natural wood covering, for which a thermoplastic sheet is prepared essentially as described above, but with the following composition:
PE 50PE 50
Ionomère copolymère 50Ionomer copolymer 50
Craie 100Chalk 100
Huile 2Oil 2
Antioxydant 0.5Antioxidant 0.5
Stéarine 0.50.5 stearin
Pigment Selon la couleur 10Pigment According to color 10
On réalise également un gâteau destiné à réaliser l'âme du revêtement comme décrit précédemment. Ensuite, pour effectuer le revêtement de sol, on dépose successivement sur une tôle de transport un contre-parement d'équilibrage qui peut éventuellement être constitué par une feuille de placage bois, le gâteau pré-aggloméré décrit précédemment présentant un poids de 6,6 kg/m2, une feuille calandrée de polyoléfine telle que décrite ci-dessus, une feuille de placage en bois d'une épaisseur de 0,6 mm et enfin une couche d'usure se présentant sous forme d'overlay mélamine. L'ensemble est soumis aux mêmes conditions que repris ci-dessus. A cake is also produced intended to produce the core of the coating as described above. Then, to carry out the floor covering, a balancing counter-facing is successively deposited on a transport sheet which may possibly consist of a wood veneer sheet, the pre-agglomerated cake described above having a weight of 6.6 kg / m 2 , a calendered polyolefin sheet as described above, a wooden veneer sheet with a thickness of 0.6 mm and finally a wear layer in the form of a melamine overlay. The assembly is subjected to the same conditions as mentioned above.

Claims

11REVENDICATIONS 11 CLAIMS
1. Procédé de fabrication d'un revêtement de sol se présentant sous forme de panneaux, dans lequel on assemble en une seule étape un envers (1) faisant fonction de contre-parement d'équilibrage, une couche intermédiaire (10) destinée à constituer l'âme du revêtement de sol et qui est essentiellement composée d'un mélange de fines particules organiques et de colle en poudre thermodurcissable et non réticulée, un parement décoratif (3) et une feuille (4) destinée à constituer la couche d'usure réalisée en un matériau thermodurcissable, le tout étant maintenu à une température comprise entre 120 et1. A method of manufacturing a floor covering in the form of panels, in which a backing (1) acting as a counter-facing is assembled in a single step, an intermediate layer (10) intended to constitute the core of the floor covering, which is essentially composed of a mixture of fine organic particles and non-crosslinked thermosetting powder glue, a decorative facing (3) and a sheet (4) intended to constitute the wear layer made of a thermosetting material, the whole being kept at a temperature between 120 and
200 °C pour une pression comprise entre 60 et 120 kg/cm2, en vue de provoquer la réticulation de la colle, caractérisé en ce que l'on incorpore lors de cette étape, entre l'âme (10) du revêtement de sol et le parement décoratif (3), une feuille en matériau thermoplastique (20) .200 ° C for a pressure between 60 and 120 kg / cm 2 , with a view to causing the crosslinking of the adhesive, characterized in that one incorporates during this step, between the core (10) of the floor covering and the decorative facing (3), a sheet of thermoplastic material (20).
2. Procédé de fabrication d'un revêtement de sol selon la revendication 1, caractérisé en ce que la feuille en matériau thermoplastique (20) sert de barrière d' étanchéité .2. Method of manufacturing a floor covering according to claim 1, characterized in that the sheet of thermoplastic material (20) serves as a sealing barrier.
3. Procédé de fabrication d'un revêtement de sol selon la revendication 1 ou 2 , caractérisé en ce que la feuille thermoplastique (20) est à base de polyolefines , en particulier à base de polyéthylène et/ou ionomères .3. Method for manufacturing a floor covering according to claim 1 or 2, characterized in that the thermoplastic sheet (20) is based on polyolefins, in particular based on polyethylene and / or ionomers.
4. Procédé de fabrication d'un revêtement de sol selon la revendication 3, caractérisé en ce que la feuille thermoplastique (20) comprend également des additifs tels qu'une charge, des huiles, des antioxydants, de la stéarine et/ou des pigments.4. Method for manufacturing a floor covering according to claim 3, characterized in that the thermoplastic sheet (20) also comprises additives such as a filler, oils, antioxidants, stearin and / or pigments .
5. Procédé de fabrication d'un revêtement de sol selon l'une quelconque des revendications précédentes, 125. Method for manufacturing a floor covering according to any one of the preceding claims, 12
caractérisé en ce que la viscosité du mélange destiné à réaliser la feuille thermoplastique (20) est adaptée de manière à éviter tout fluage lors de l'étape d'assemblage.characterized in that the viscosity of the mixture intended to produce the thermoplastic sheet (20) is adapted so as to avoid any creep during the assembly step.
6. Procédé de fabrication d'un revêtement de sol selon l'une quelconque des revendications précédentes, caractérisé en ce que la composition de la feuille thermoplastique (20) est choisie en fonction de son adaptabilité à l'étape d'assemblage à la température entre6. A method of manufacturing a floor covering according to any one of the preceding claims, characterized in that the composition of the thermoplastic sheet (20) is chosen according to its adaptability to the assembly step at temperature Between
120 et 200 °C pour une pression comprise entre 60 et 120 kg/m .120 and 200 ° C for a pressure between 60 and 120 kg / m.
7. Procédé de fabrication d'un revêtement de sol selon l'une quelconque des revendications précédentes, caractérisé en ce que la feuille thermoplastique (20) est disposée (sans adjonction de colle) entre l'âme (10) du revêtement de sol et le parement décoratif (3) .7. A method of manufacturing a floor covering according to any one of the preceding claims, characterized in that the thermoplastic sheet (20) is disposed (without the addition of glue) between the core (10) of the floor covering and the decorative facing (3).
8. Procédé de fabrication d'un revêtement de sol selon l'une quelconque des revendications précédentes, caractérisé en ce que l'on ajoute entre l'envers (1) et l'âme (10) du revêtement de sol également une seconde feuille en matériau thermoplastique.8. Method for manufacturing a floor covering according to any one of the preceding claims, characterized in that a second sheet is added between the back (1) and the core (10) of the floor covering made of thermoplastic material.
9. Procédé de fabrication d'un revêtement de sol selon l'une quelconque des revendications précédentes, caractérisé en ce que la couche intermédiaire (10) destinée à constituer l'âme est constituée par un mélange sec de fines particules organiques et de colle en poudre non réticulée, ce mélange étant légèrement tassé au moyen d'un rouleau afin que l'on puisse y déposer successivement le parement décoratif (3) et éventuellement la feuille (4) destinée à former la couche d'usure. 9. A method of manufacturing a floor covering according to any one of the preceding claims, characterized in that the intermediate layer (10) intended to constitute the core consists of a dry mixture of fine organic particles and glue in non-crosslinked powder, this mixture being lightly compacted by means of a roller so that the decorative facing (3) and possibly the sheet (4) intended to form the wear layer can be deposited there successively.
10. Procédé de fabrication d'un revêtement de sol selon l'une quelconque des revendications 1 à 8, caractérisé en ce que la couche intermédiaire (10) est constituée par un gâteau obtenu préalablement à l'étape 1310. A method of manufacturing a floor covering according to any one of claims 1 to 8, characterized in that the intermediate layer (10) consists of a cake obtained prior to step 13
d'assemblage en moulant le mélange de fines particules organiques et de colle en poudre essentiellement non réticulée à basse température et sous pression.assembly by molding the mixture of fine organic particles and glue powder essentially uncrosslinked at low temperature and under pressure.
11. Procédé de fabrication d'un revêtement de sol selon la revendication 10, caractérisé en ce que l'on travaille pour l'étape de fabrication de préparation du gâteau à une température comprise entre 50 et 100 °C et une pression comprise entre 30 et 100 kg/m2.11. A method of manufacturing a floor covering according to claim 10, characterized in that one works for the manufacturing step of preparing the cake at a temperature between 50 and 100 ° C and a pressure between 30 and 100 kg / m 2 .
12. Procédé de fabrication d'un revêtement de sol selon l'une quelconque des revendications précédentes, caractérisé en ce que les fines particules organiques sont constituées par de la farine de bois et/ou des fibres telles que des fibres de cellulose et auxquelles on ajoute éventuellement d'autres particules synthétiques plus dures. 12. Method of manufacturing a floor covering according to any one of the preceding claims, characterized in that the fine organic particles consist of wood flour and / or fibers such as cellulose fibers and to which possibly adding other harder synthetic particles.
13. Procédé de fabrication d'un revêtement de sol selon l'une quelconque des revendications précédentes, caractérisé en ce que la colle en poudre utilisée est une colle du type phénoplaste ou aminoplaste ou encore polyuréthane . 13. A method of manufacturing a floor covering according to any one of the preceding claims, characterized in that the powder adhesive used is an adhesive of the phenoplast or aminoplast or polyurethane type.
14. Revêtement de sol à parement synthétique ou bois obtenu par le procédé selon l'une quelconque des revendications précédentes, caractérisé en ce qu'il comprend successivement un contre-parement (1) destiné à constituer l'envers, une âme (10) essentiellement composée d'un mélange de particules organiques et d'une colle thermodurcissable réticulée exempte de solvant, une feuille en matériau thermoplastique (20), un parement décoratif (3) de type papier mélamine imprimé ou même bois, associés à une couche d'usure (4) superficielle réalisée en un matériau thermodurcissable. 14. Flooring with synthetic or wood facing obtained by the method according to any one of the preceding claims, characterized in that it successively comprises a counter facing (1) intended to constitute the back, a core (10) essentially composed of a mixture of organic particles and of a crosslinked thermosetting adhesive free of solvent, a sheet of thermoplastic material (20), a decorative facing (3) such as printed melamine paper or even wood, associated with a layer of surface wear (4) made of a thermosetting material.
EP99917840A 1998-04-15 1999-03-17 Method for producing a floor covering with natural or synthetic wood facing and resulting product Withdrawn EP1085978A1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
EP99917840A EP1085978A1 (en) 1998-04-15 1999-03-17 Method for producing a floor covering with natural or synthetic wood facing and resulting product

Applications Claiming Priority (6)

Application Number Priority Date Filing Date Title
US8179798P 1998-04-15 1998-04-15
US81797P 1998-04-15
EP98202184 1998-06-29
EP98202184A EP0950510A1 (en) 1998-04-15 1998-06-29 Method for the manufacture of a natural or synthetic wood floor covering and articles so obtained
EP99917840A EP1085978A1 (en) 1998-04-15 1999-03-17 Method for producing a floor covering with natural or synthetic wood facing and resulting product
PCT/EP1999/001954 WO1999052709A1 (en) 1998-04-15 1999-03-17 Method for producing a floor covering with natural or synthetic wood facing and resulting product

Publications (1)

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EP1085978A1 true EP1085978A1 (en) 2001-03-28

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EP98202184A Withdrawn EP0950510A1 (en) 1998-04-15 1998-06-29 Method for the manufacture of a natural or synthetic wood floor covering and articles so obtained
EP99917840A Withdrawn EP1085978A1 (en) 1998-04-15 1999-03-17 Method for producing a floor covering with natural or synthetic wood facing and resulting product

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AU (1) AU3597999A (en)
CA (1) CA2329609A1 (en)
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US7875655B2 (en) 2006-01-20 2011-01-25 Material Innovations, Llc Carpet waste composite
WO2009135323A1 (en) * 2008-05-08 2009-11-12 Uniboard Canada Inc. Manufacturing process for a laminated structure
CN102307723B (en) 2008-12-19 2014-06-04 纤维复合有限责任公司 Wood-plastic composites utilizing ionomer capstocks and methods of manufacture
US11572646B2 (en) 2020-11-18 2023-02-07 Material Innovations Llc Composite building materials and methods of manufacture

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US3859766A (en) * 1973-03-26 1975-01-14 Simplex Ind Inc Wall structure for modular or mobile homes
SU589138A1 (en) * 1976-08-03 1978-01-25 Всесоюзный Научно-Исследовательский Институт Деревообрабатывающей Промышленности Method of lining wooden boards
GB2238015A (en) * 1989-11-15 1991-05-22 Du Pont Canada Panel.
JP3074342B2 (en) * 1994-03-31 2000-08-07 朝日ウッドテック株式会社 Floor panel
CA2194073A1 (en) * 1994-08-01 1996-02-15 Albert Roussel Method for the manufacture of a natural or synthetic wood floor covering and articles so obtained
JPH09314523A (en) * 1996-05-27 1997-12-09 Dantani Plywood Co Ltd Woody decorative board
JPH10109380A (en) * 1996-10-07 1998-04-28 Dantani Plywood Co Ltd Decorative board and flush panel

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Title
See references of WO9952709A1 *

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WO1999052709A1 (en) 1999-10-21
AU3597999A (en) 1999-11-01
NO20005025D0 (en) 2000-10-05
NO20005025L (en) 2000-12-15
CA2329609A1 (en) 1999-10-21

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