EP1762400B1 - Floor panel having polyurethane layers and a decorative layer - Google Patents

Floor panel having polyurethane layers and a decorative layer Download PDF

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Publication number
EP1762400B1
EP1762400B1 EP20060017623 EP06017623A EP1762400B1 EP 1762400 B1 EP1762400 B1 EP 1762400B1 EP 20060017623 EP20060017623 EP 20060017623 EP 06017623 A EP06017623 A EP 06017623A EP 1762400 B1 EP1762400 B1 EP 1762400B1
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EP
European Patent Office
Prior art keywords
floor panel
layer
polyurethane layer
panel according
decorative layer
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EP20060017623
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German (de)
French (fr)
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EP1762400A1 (en
EP1762400B2 (en
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Flooring Technologies Ltd
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Flooring Technologies Ltd
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Application filed by Flooring Technologies Ltd filed Critical Flooring Technologies Ltd
Priority to PL06017623T priority Critical patent/PL1762400T5/en
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B44—DECORATIVE ARTS
    • B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
    • B44C5/00—Processes for producing special ornamental bodies
    • B44C5/04—Ornamental plaques, e.g. decorative panels, decorative veneers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B44—DECORATIVE ARTS
    • B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
    • B44C5/00—Processes for producing special ornamental bodies
    • B44C5/04—Ornamental plaques, e.g. decorative panels, decorative veneers
    • B44C5/043—Ornamental plaques, e.g. decorative panels, decorative veneers containing wooden elements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B44—DECORATIVE ARTS
    • B44F—SPECIAL DESIGNS OR PICTURES
    • B44F9/00—Designs imitating natural patterns
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/02—Flooring or floor layers composed of a number of similar elements
    • E04F15/10—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials

Definitions

  • Floor panel in particular made of wood material, plastic or a mixture of wood material and plastic, with a top and a bottom and side edges, in which at least on the top of a noise reduction during walking elastic polyurethane layer is applied with a decorative layer applied thereto.
  • Such a floor panel is for example from the DE-A-10 2004 031 547 known.
  • Such panels have disadvantages, because wood-based materials have hygroscopic properties, which result in swelling and shrinkage size changes in the wood materials, which cause such floor panels are not used in wet rooms.
  • floor panels are often provided with hard, wear-resistant surfaces that create disturbing noises when walking and counteract the natural effect that laminate floors are designed to produce.
  • Laminates are known, on the plate-shaped base at least one decor-supporting paper layer is applied.
  • a coating of a polyurethane-based two-component paint as a binder is applied to a support plate, then a coating of color flakes, which consist of polyvinyl acetate and / or polyvinyl acrylate flakes on this.
  • This coating is applied to the still fresh paint layer.
  • a surface finish coating is applied from a polyurethane-based one-component paint with a binder.
  • the decor imitates a look in the look and feel of a natural material, such as wood or stone.
  • the decor may also have an embossed structure.
  • a disadvantage is the cost-intensive production by the use of decorated and impregnated paper layers as well as their exact alignment on the plate-shaped base and their exact alignment with respect to a the embossment structure introducing tool.
  • the control of the pressure and temperature conditions on the one hand and the control of the process speed on the other hand are also costly.
  • the imitated decor is printed on a paper web, which is then coated with synthetic resin and rolled up on a roll.
  • the thus prepared decorative sheet is then applied to the panel manufacturer on wood fiber boards.
  • the paper web changes in size.
  • the US-A-3,890,415 describes a decorative, particularly lightweight box girder, which is characterized by particularly thin side walls and a particularly thin bottom.
  • the side walls and the floor are made of plastic.
  • the box girder In order to give the box girder a visually appealing surface, it can be painted and a wood structure embossed.
  • a non-hardened, foaming polyurethane plastic is introduced into a box girder mold into which an inlay has been inserted whose surface has a wood structure.
  • floor panels are to be provided which mimic natural materials almost perfectly and can also be used in damp rooms. Furthermore, the properties relating to the noise during walking should be improved.
  • the generic floor panel is characterized by the features in the characterizing part of claim 1.
  • the floor panel can carry a first layer of polyurethane both on the bottom and on the top.
  • the underside polyurethane layer serves as a so-called counter-pull to avoid a tipping of the floor panel.
  • the lower-side polyurethane layer since it is elastic, can also be used as a sound-insulating layer. Due to the elastic, top-side polyurethane layer can be reduced according to the invention, the noise when walking the floor panel.
  • the top-side polyurethane layer seals the floor panel from the ingress of moisture, so that it can also be used in damp rooms.
  • the bottom polyurethane layer may contain admixtures to the polyurethane of heavier particles such as sands, flours or dusts of quartz, granite or marble or metal particles.
  • the underside polyurethane layer contains color particles to meet different demands on the optical design of the building board.
  • top-side polyurethane layer serves as a primer and / or as a primer for a subsequent, composed of one or more individual layers, decorative layer.
  • the decorative layer may consist of one or more individual layers in order to realize even elaborate decors.
  • a final or sealing polyurethane layer is applied to the decorative layer in order to protect the decorative layer, for example, against mechanical influences caused by walking and damage caused by moisture.
  • the upper polyurethane layer may have a structural embossing, which is tuned, for example, to a wood decor of the decorative layer to be imitated.
  • the application rate of the final polyurethane layer for weak embossing is between 50 and 100 g / m 2 and for heavy embossing between 100 and 400 g / m 2 .
  • corundum may be added to the final polyurethane layer as wear-inhibiting particles.
  • the final polyurethane layer can contain as an effect-generating particles such as metals or color pigments to meet a variety of demands on the optical design can.
  • the uppermost polyurethane layer can also be monochrome.
  • the final polyurethane layer may contain optically brightening or antistatic admixtures. It is also conceivable for the polyurethane layer to have an antibacterial effect and / or add dirt-repellent admixtures in order to produce floor panels for special applications with increased hygiene requirements.
  • the polyurethane layer can be adjusted by the variation of the composition of the polyurethane layer, the gloss level of the surface to meet the different optical requirements of the various applications.
  • both the bottom and the top of the floor panel can be given the same layer structure.
  • a lower-surface structure has an anti-slip effect on the ground.
  • the top and bottom decorative layer and patterning give the impression of a nearly perfect imitation of a natural material, e.g. Wood or stone, still reinforce
  • connection means on the side edges of the floor panel For example, tongue and groove, formed to connect a plurality of floor panels with each other. It has been shown that it is particularly advantageous when mechanical locking means for locking a plurality of floor panels are integrally formed with each other on the connecting means, so that in addition to the connection of a plurality of floor panels with each other and a mechanical locking of the floor panels is possible without an additional gluing.
  • a natural material for example wood or stone
  • the decorative layer and / or the structuring embossing are adapted to the decor located on the surface.
  • a natural material mimicking decorative layer is placed on the polyurethane layer.
  • the polyurethane layer be supported by pouring and doctoring on, so that a flat surface is formed on the provided with a decorative layer top of the floor panel.
  • the decorative layer applied to the polyurethane layer may also be applied by one or more rolling mills to apply different colors or multi-layer decors to the surface of the floor panel.
  • the decorative layer can also be applied by at least one digital printer or printed by screen printing. Due to the different ways to bake the decorative layer on the top of the floor panel, the respective technical requirements can be discussed.
  • the decorative layer can be applied in one layer or in several layers. If the decorative layer is applied in several layers, a relief-like surface can already be produced by the decorative layer, which can imitate a natural surface, for example a wooden surface, with particular accuracy.
  • a final polyurethane layer is applied to the decorative layer, on the one hand to protect the decorative layer against Abrich and other mechanical influences and on the other to improve the sound-insulating properties of the floor panel.
  • the order can be carried out by a roller printing unit.
  • a customized to the respective requirements thick or very thin final polyurethane layer can be embroidered.
  • the drying of the respective last polyurethane layer can take place to the multilayer structure of the final polyurethane layer to allow and also to realize very thick polyurethane layers, in which particularly deep imprints can be introduced.
  • the drying process can be active, for example by a fan heater, or passively, for example by venting in the ambient air done.
  • the division of a large floor panel in several individual small floor panels can be done by means of a plurality of dividing saws.
  • other distribution methods such as water jet cutting, can be used.
  • edges can be at least partially decorated and / or receive a structuring embossing.
  • the decoration and / or the structuring embossing is adapted to the decor located on the surface. This enhances the impression of a perfect imitation of a natural material.
  • Fig. 1 shows the cross section of the floor panel with a top 1 and a bottom 2.
  • a polyurethane layer 3 is applied as primer and adhesion promoter, on the bottom 2, a polyurethane layer 4 is applied as a back-up.
  • a decorative layer 5 is applied, which has a decorating a natural material decor.
  • the order of the polyurethane layers 3 and 4 is carried out by a roller printing unit 17 and the order of the decorative layer 5 on the polyurethane layer 3 is carried out with a rolling mill 18.
  • a final polyurethane layer 6 is applied, which is thicker than the first polyurethane layer 3 and consists of several layers.
  • a structure-forming embossment 7 is introduced by means of a roller printing unit 17, which imitates a natural material and is adapted to the structure of the decorative layer 5.
  • Fig. 2 shows the top view of the top 1 of the floor panel on the first polyurethane layer 3, a wood grain imitating decorative layer 5 and a final polyurethane layer 6 is applied.
  • a structuring embossment 7 is embossed, which imitates a natural material, here a wood structure.
  • On the side edges 10 and 13 grooves 14 are formed as connecting means.
  • At the opposite side edges 11 and 12 springs 15 are formed as a corresponding connecting means.
  • Fig. 3 shows a device for producing the floor panel.
  • a polyurethane layer 4 is applied to the bottom 2 of the floor panel as a countermatch to prevent burring.
  • the polyurethane layer 4 is applied to the polyurethane layer 4 by means of the rolling mill 18, a natural material imitating decorative layer 5.
  • the second polyurethane layer 5 is applied by means of the roller printing unit 19.
  • the final polyurethane layer 6 is dried.
  • a structure-embossing 7 embossed in order to enhance the natural impression of the floor panel yet.

Abstract

The slab has an upper side (1) and a lower side (2), where a polyurethane layer (3) is applied on the upper side. A decorative layer (5) imitating the natural material e.g. wood or stone, is applied on the polyurethane layer. Another polyurethane layer (4) is applied on the lower side, where the polyurethane layer (4) contains heavier particles opposite to the polyurethane. A third polyurethane layer (6) is applied on the decorative layer, where the polyurethane layer (6) seals the decorative layer. An independent claim is also included for a method for producing a building slab.

Description

Fußbodenpaneel, insbesondere aus Holzwerkstoff, Kunststoff oder einem Gemisch aus Holzwerkstoff und Kunststoff, mit einer Oberseite und einer Unterseite und Seitenkanten, bei dem zumindest auf die Oberseite eine zur Geräuschreduzierung beim Begehen elastische Polyurethanschicht mit einer darauf aufgebrachten Dekorschicht aufgebracht ist.Floor panel, in particular made of wood material, plastic or a mixture of wood material and plastic, with a top and a bottom and side edges, in which at least on the top of a noise reduction during walking elastic polyurethane layer is applied with a decorative layer applied thereto.

Ein solches Fußbodenpaneel ist beispielsweise aus der DE-A-10 2004 031 547 bekannt. Solche Paneele weisen Nachteile auf, denn Holzwerkstoffe besitzen hygroskopische Eigenschaften, wodurch sich durch Quellen und Schwinden Größenveränderungen in den Holzwerkstoffen ergeben, die dazu führen, dass solche Bodenpaneele in Feuchträumen nicht einsetzbar sind.Such a floor panel is for example from the DE-A-10 2004 031 547 known. Such panels have disadvantages, because wood-based materials have hygroscopic properties, which result in swelling and shrinkage size changes in the wood materials, which cause such floor panels are not used in wet rooms.

Fußbodenpaneele sind zudem häufig mit harten, verschleißfesten Oberflächen versehen, die beim Gehen störende Geräusche erzeugen und dem natürlichen Effekt, die Laminatfußböden erzeugen sollen, entgegenwirken.In addition, floor panels are often provided with hard, wear-resistant surfaces that create disturbing noises when walking and counteract the natural effect that laminate floors are designed to produce.

Bekannt sind auch Bodenpaneele, deren Basismaterial bereits aus wasserfestem Material, beispielsweise Kunststoff besteht. Solche Kunststoffmaterialien lassen sich jedoch nicht mit harzimprägnierten Dekor- und Overlaypapieren unter erhöhtem Druck und unter erhöhter Temperatur verpressen.Also known are floor panels whose base material already consists of waterproof material, such as plastic. However, such plastic materials can not be pressed with resin-impregnated decorative and overlay papers under elevated pressure and at elevated temperature.

Bekannt sind Laminate, auf deren plattenförmiger Basis mindestens eine dekortragende Papierlage aufgebracht ist. Bei einer aus der EP-A2-1 099 736 bekannten Frontplatte für ein Möbelstück wird auf eine Trägerplatte eine Beschichtung aus einem auf Polyurethan-Basis bestehenden Zwei-KomponentenLack als Bindemittel aufgebracht, auf diese anschließend eine Beschichtung aus Farbflocken, die aus Polyvinylacetat und/oder Polyvinylacrylat-Flocken bestehen. Diese Beschichtung wird auf die noch frische Lackschicht aufgebracht. Anschließend wird eine Oberflächenabschlussbeschichtung aus einem auf Polyurethanbasis hergestellten Ein-Komponentenlack mit einem Bindemittel aufgebracht.Laminates are known, on the plate-shaped base at least one decor-supporting paper layer is applied. At one of the EP-A2-1 099 736 known front panel for a piece of furniture is applied to a support plate, a coating of a polyurethane-based two-component paint as a binder, then a coating of color flakes, which consist of polyvinyl acetate and / or polyvinyl acrylate flakes on this. This coating is applied to the still fresh paint layer. Subsequently, a surface finish coating is applied from a polyurethane-based one-component paint with a binder.

Das Dekor imitiert dabei allgemein in Optik und Haptik einen natürlichen Werkstoff, wie beispielsweise Holz oder Stein. Dazu kann das Dekor auch eine Prägestruktur aufweisen. Nachteilig ist die kostenintensive Herstellung durch die Verwendung dekorierter und imprägnierter Papierlagen sowie deren genaue Ausrichtung auf der plattenförmigen Basis und deren genaue Ausrichtung bezüglich eines die Prägestruktur einbringenden Werkzeugs. Die Steuerung der Druck- und Temperaturverhältnisse einerseits und die Steuerung der Prozessgeschwindigkeit andererseits sind ebenfalls kostenintensiv.The decor imitates a look in the look and feel of a natural material, such as wood or stone. For this purpose, the decor may also have an embossed structure. A disadvantage is the cost-intensive production by the use of decorated and impregnated paper layers as well as their exact alignment on the plate-shaped base and their exact alignment with respect to a the embossment structure introducing tool. The control of the pressure and temperature conditions on the one hand and the control of the process speed on the other hand are also costly.

Das imitierte Dekor wird auf eine Papierbahn aufgedruckt, die anschließend mit Kunstharz beschichtet und auf eine Rolle aufgerollt wird. Die so vorgefertigte Dekorbahn wird anschließend bei dem Paneelhersteller auf Holzfaserplatten aufgebracht. Durch das Aufdrucken des Dekors auf die Papierbahn, das spätere Versiegeln der Papierbahn mit Kunstharz und das anschließende durch Druck- und Temperatureinwirkung Verbinden der Dekorschicht mit der Holzwerkstoffplatte, verändert sich die Papierbahn in ihren Abmessungen. Der Fachmann spricht davon, dass das Papier wächst. Das Papier wächst sowohl in der Länge (Längenwachstum) als auch in der Breite (Breitenwachstum). Wenn diese Dekorplatte nun zu einzelnen Paneelen zugeschnitten werden soll, muss das Längen- und Breitenwachstum berücksichtigt werden, weil anderenfalls eine ungleiche Dekorverteilung auf den einzelnen Paneelen vorhanden wäre. Dies hätte zur Folge, dass der aus einer ungleich verteilten Dekorschicht zusammengesetzte Fußboden an den Verbindungskanten der Paneele Dekorsprünge aufweist. Selbst wenn solche Dekorsprünge nur wenige Millimeter betragen, fallen sie bei der Betrachtung auf, was den ästhetischen Eindruck negativ beeinflusst und damit die Qualität des ausgelegten Fußbodens mindert. Um qualitätsgerecht produzieren zu können, muss das Papierwachstum erfasst und die Säge entsprechend eingestellt werden, was weiterhin die Herstellung der Paneele verteuert.The imitated decor is printed on a paper web, which is then coated with synthetic resin and rolled up on a roll. The thus prepared decorative sheet is then applied to the panel manufacturer on wood fiber boards. By printing the decoration on the paper web, the subsequent sealing of the paper web with synthetic resin and the subsequent pressure and temperature effect connecting the decorative layer with the wood-based panel, the paper web changes in size. The expert speaks of the paper growing. The paper grows both in length (length growth) and in width (width growth). If this decorative panel is now to be cut to individual panels, the length and width growth must be taken into account, because otherwise an uneven decor distribution on the individual panels would be present. This would mean that the floor composed of an unequally distributed decorative layer has decorative jumps on the connecting edges of the panels. Even if such decorative jumps are only a few millimeters, they are noticeable when viewed, which adversely affects the aesthetic impression and thus reduces the quality of the floor designed. In order to produce quality, paper growth must be recorded and the saw adjusted accordingly, which further increases the cost of manufacturing the panels.

Die US-A-3,890,415 beschreibt einen dekorativen, besonders leichten Kastenträger, der sich durch besonders dünne Seitenwände und einen besonders dünnen Boden auszeichnet. Die Seitenwände und der Boden bestehen dabei aus Kunststoff. Um dem Kastenträger eine optisch ansprechende Oberfläche zu verleihen, kann diese lackiert und eine Holzstruktur eingeprägt werden. Dazu wird bei der Herstellung der Kastenträger ein nicht ausgehärteter, aufschäumender Polyurethan-Kunststoff in eine Kastenträgerform eingebracht, in die eine Einlage eingelegt wurde, deren Oberfläche eine Holzstruktur aufweist.The US-A-3,890,415 describes a decorative, particularly lightweight box girder, which is characterized by particularly thin side walls and a particularly thin bottom. The side walls and the floor are made of plastic. In order to give the box girder a visually appealing surface, it can be painted and a wood structure embossed. For this purpose, in the production of the box girder, a non-hardened, foaming polyurethane plastic is introduced into a box girder mold into which an inlay has been inserted whose surface has a wood structure.

Von dieser Problemstellung ausgehend, sollen Fußbodenpaneele bereitgestellt werden, die natürliche Werkstoffe nahezu perfekt imitieren und zusätzlich in Feuchträumen einsetzbar sind. Weiterhin sollen die Eigenschaften bezüglich der Geräuschbildung beim Begehen verbessert werden. Zur Problemlösung zeichnet sich das gattungsgemäße Fußbodenpaneel durch die Merkmale im kennzeichnenden Teil des Anspruchs 1 aus.Based on this problem, floor panels are to be provided which mimic natural materials almost perfectly and can also be used in damp rooms. Furthermore, the properties relating to the noise during walking should be improved. To solve the problem, the generic floor panel is characterized by the features in the characterizing part of claim 1.

Das Fußbodenpaneel kann sowohl auf der Unter- als auch auf der Oberseite eine erste Polyurethanschicht tragen. Vorteilhafterweise dient die unterseitige Polyurethanschicht dabei als so genannter Gegenzug zur Vermeidung einer Schüsselung des Fußbodenpaneels. Zudem kann die unterseitige Polyurethanschicht, da sie elastisch ist, auch als schalldämmende Schicht Verwendung finden. Durch die elastische, oberseitige Polyurethanschicht kann erfindungsgemäß die Geräuschbildung beim Begehen des Fußbodenpaneels reduziert werden. Zudem versiegelt die oberseitige Polyurethanschicht das Fußbodenpaneel vor dem Eindringen von Feuchtigkeit, so dass sie auch in Feuchträumen eingesetzt werden kann.The floor panel can carry a first layer of polyurethane both on the bottom and on the top. Advantageously, the underside polyurethane layer serves as a so-called counter-pull to avoid a tipping of the floor panel. In addition, the lower-side polyurethane layer, since it is elastic, can also be used as a sound-insulating layer. Due to the elastic, top-side polyurethane layer can be reduced according to the invention, the noise when walking the floor panel. In addition, the top-side polyurethane layer seals the floor panel from the ingress of moisture, so that it can also be used in damp rooms.

Um die schalldämmenden Eigenschaften der Polyurethanschicht weiter zu verbessern, kann die unterseitige Polyurethanschicht Beimengungen gegenüber dem Polyurethan schwererer Partikel wie Sande, Mehle oder Stäube von Quarz, Granit oder Marmor oder Metallteilchen enthalten.In order to further improve the sound insulating properties of the polyurethane layer, the bottom polyurethane layer may contain admixtures to the polyurethane of heavier particles such as sands, flours or dusts of quartz, granite or marble or metal particles.

Es ist auch möglich, dass die unterseitige Polyurethanschicht Farbpartikel enthält, um unterschiedlichen Ansprüchen an die optische Gestaltung der Bauplatte gerecht zu werden.It is also possible that the underside polyurethane layer contains color particles to meet different demands on the optical design of the building board.

Darüber hinaus dient die oberseitige Polyurethanschicht als Grundierung und/oder als Haftvermittler für eine nachfolgende, sich aus einer oder mehreren Einzelschichten zusammensetzende, Dekorschicht. Hierdurch ist das Aufbringen eines mit Harz imprägnierten Dekorpapiers nicht mehr notwendig, so dass sich hier erhebliche Kosteneinsparpotentiale für die Herstellung von Bauplatten ergeben.In addition, the top-side polyurethane layer serves as a primer and / or as a primer for a subsequent, composed of one or more individual layers, decorative layer. As a result, the application of a resin-impregnated decor paper is no longer necessary, so that there are significant cost savings potential for the production of building boards here.

Je nach dem wie dick die Dekorschicht auf die Polyurethanschicht aufgetragen werden soll, kann die Dekorschicht aus einer oder mehreren Einzelschichten bestehen, um auch aufwändige Dekore realisieren zu können.Depending on how thick the decorative layer is to be applied to the polyurethane layer, the decorative layer may consist of one or more individual layers in order to realize even elaborate decors.

Auf die Dekorschicht wird erfindungsgemäß eine abschließende bzw. versiegelnde Polyurethanschicht aufgetragen, um die Dekorschicht beispielsweise vor mechanischen Einwirkungen durch Begehen sowie vor Beschädigungen durch Feuchteeinwirkung zu schützen. Damit das Fußbodenpaneel einen natürlichen Werkstoff besonders genau imitieren kann, kann die obere Polyurethanschicht eine Strukturprägung aufweisen, die beispielsweise auf ein zu imitierendes Holzdekor der Dekorschicht abgestimmt ist.According to the invention, a final or sealing polyurethane layer is applied to the decorative layer in order to protect the decorative layer, for example, against mechanical influences caused by walking and damage caused by moisture. So that the floor panel can imitate a natural material very precisely, the upper polyurethane layer may have a structural embossing, which is tuned, for example, to a wood decor of the decorative layer to be imitated.

Vorteilhafterweise beträgt die Auftragsmenge der abschließenden Polyurethanschicht für schwache Prägungen zwischen 50 und 100 g/m2 und für starke Prägungen zwischen 100 und 400 g/m2.Advantageously, the application rate of the final polyurethane layer for weak embossing is between 50 and 100 g / m 2 and for heavy embossing between 100 and 400 g / m 2 .

Um die Abriebfestigkeit der abschließenden Polyurethanschicht weiter zu verbessem, können der abschließenden Polyurethanschicht als verschleißhemmende Partikel Korund beigegeben werden.In order to further improve the abrasion resistance of the final polyurethane layer, corundum may be added to the final polyurethane layer as wear-inhibiting particles.

Die abschließende Polyurethanschicht kann als effekterzeugende Partikel wie Metalle oder Farbpigmente enthalten, um verschiedensten Ansprüchen an die optische Gestaltung gerecht werden zu können. So kann die oberste Polyurethanschicht zum Beispiel auch einfarbig sein.The final polyurethane layer can contain as an effect-generating particles such as metals or color pigments to meet a variety of demands on the optical design can. For example, the uppermost polyurethane layer can also be monochrome.

Optional oder in Kombination mit den zuvor genannten Varianten kann die abschließende Polyurethanschicht optisch aufhellende oder auch antistatisch wirkende Beimengungen enthalten, Es ist auch denkbar, der Polyurethanschicht antibakteriell wirkende und/oder schmutzabweisende Beimengungen zuzugeben, um Fußbodenpaneele für spezielle Anwendungsgebiete mit erhöhten Anforderungen an Hygiene herstellen zu können. Vorteilhafterweise kann durch die Variation der Zusammensetzung der Polyurethanschicht der Glanzgrad der Oberfläche eingestellt werden, um auch den unterschiedlichen optischen Anforderungen der verschiedenen Einsatzgebiete gerecht zu werden.Optionally or in combination with the abovementioned variants, the final polyurethane layer may contain optically brightening or antistatic admixtures. It is also conceivable for the polyurethane layer to have an antibacterial effect and / or add dirt-repellent admixtures in order to produce floor panels for special applications with increased hygiene requirements. Advantageously, can be adjusted by the variation of the composition of the polyurethane layer, the gloss level of the surface to meet the different optical requirements of the various applications.

Alternativ können sowohl die Unter- als auch die Oberseite des Fußbodenpaneels einen gleichen Schichtaufbau erhalten. Eine unterseitige strukturgebende Prägung hat dabei neben optischen und haptischen Effekten eine rutsehhemmende Wirkung auf dem Untergrund. Durch die ober- und unterseitige Dekorschicht und strukturierung lässt sich der Eindruck einer nahezu perfekten Imitation eines natürlichen Werkstoffes, z.B. Holz oder Stein, noch verstärkenAlternatively, both the bottom and the top of the floor panel can be given the same layer structure. In addition to optical and haptic effects, a lower-surface structure has an anti-slip effect on the ground. The top and bottom decorative layer and patterning give the impression of a nearly perfect imitation of a natural material, e.g. Wood or stone, still reinforce

Vorteilhafterweise sind an den Seitenkanten des Fußbodenpaneels zueinander korrespondierende Verbindungsmittel. zum Beispiel Nut und Feder, angeformt, um eine Mehrzahl von Fußbodenpaneelen untereinander zu verbinden. Es hat sich gezeigt, dass es besonders vorteilhaft ist wenn an den Verbindungsmitteln mechanische Verriegelungsmittel zur Verriegelung mehreren Fußbodenpaneele untereinander angeformt sind, damit neben der Verbindung einer Mehrzahl von Fußbodenpaneelen untereinander auch eine mechanische Verriegelung der Fußbodenpaneele ohne eine zusätzliche Verleimung möglich ist.Advantageously, mutually corresponding connection means on the side edges of the floor panel. For example, tongue and groove, formed to connect a plurality of floor panels with each other. It has been shown that it is particularly advantageous when mechanical locking means for locking a plurality of floor panels are integrally formed with each other on the connecting means, so that in addition to the connection of a plurality of floor panels with each other and a mechanical locking of the floor panels is possible without an additional gluing.

Um einen natürlichen Werkstoff, zum Beispiel Holz oder Stein, besonders präzise zu imitieren, ist es vorteilhaft auch auf den Kanten des Fußbodenpaneels eine den jeweiligen natürlichen Werkstoff imitierende Dekorschicht aufzubringen. Um den zu imitierenden Werkstoff noch genauer nachzubilden, ist es vorteilhaft eine den jeweiligen natürlichen Werkstoff imitierende strukturgebende Prägung auch in die Polyurethanabdeckschicht der Seitenkanten des Fußbodenpaneels einzuprägen. Vorzugsweise sind dabei die Dekorschicht und/oder die strukturgebende Prägung auf das auf der Oberfläche befindliche Dekor angepasst.In order to imitate a natural material, for example wood or stone, particularly precisely, it is also advantageous to apply a decorative layer imitating the respective natural material on the edges of the floor panel. In order to simulate the material to be imitated even more precisely, it is advantageous to impress a structure-imprinting embossing mimicking the respective natural material into the polyurethane covering layer of the side edges of the floor panel. Preferably, the decorative layer and / or the structuring embossing are adapted to the decor located on the surface.

Bei der Herstellung eines Fußbodenpaneels wird auf die Polyurethanschicht eine einen natürlichen Werkstoff imitierende Dekorschicht auf gebracht. Beispielsweise kann die Polyurethanschicht dabei durch Aufgießen und Abrakeln auf getragen werden, so dass eine ebene Oberfläche auf der mit einer Dekorschicht versehenen Oberseite des Fußbodenpaneels entsteht.In the manufacture of a floor panel, a natural material mimicking decorative layer is placed on the polyurethane layer. For example, the polyurethane layer be supported by pouring and doctoring on, so that a flat surface is formed on the provided with a decorative layer top of the floor panel.

Die Dekorschicht, die auf die Polyurethansehicht aufgetragen wird, kann auch durch ein oder mehrere Walzwerke aufgetragen werden, um unterschiedlichen Farben oder mehrsehiehtige Dekore auf die Oberfläche des Fußbodenpaneels aufbringen zu kennen.The decorative layer applied to the polyurethane layer may also be applied by one or more rolling mills to apply different colors or multi-layer decors to the surface of the floor panel.

Alternativ kann die Dekorschicht auch durch mindestens einen Digitaldrucker aufgebracht werden oder im Siebdruckverfahren aufgedruckt werden. Durch die verschiedenen Möglichkeiten, die Dekorschicht auf die Oberseite des Fußbodenpaneels aufzubrinen, kann auf die jeweiligen anlagentechnischen Voraussetzungen eingegangen werden.Alternatively, the decorative layer can also be applied by at least one digital printer or printed by screen printing. Due to the different ways to bake the decorative layer on the top of the floor panel, the respective technical requirements can be discussed.

Je nach optischen Erfordernissen kann die Dekorschicht in einer Schicht oder in mehreren Schichten aufgetragen werden. Wird die Dekorschicht in mehreren Schichten aufgetragen, so kann schon durch die Dekorschicht eine reliefartige Oberfläche erzeugt werden, die eine natürliche Oberfläche, zum Beispiel eine Holzoberfläche, besonders genau imitieren kann.Depending on the optical requirements, the decorative layer can be applied in one layer or in several layers. If the decorative layer is applied in several layers, a relief-like surface can already be produced by the decorative layer, which can imitate a natural surface, for example a wooden surface, with particular accuracy.

Vorteilhafterweise wird auf die Dekorschicht eine abschließende Polyurethanschicht aufgetragen, um zum einen die Dekorschicht vor Abrich und anderen mechanischen Einflüssen zu schützen und zum anderen die schalldämmenden Eigenschaften des Fußbodenpaneels zu verbessern.Advantageously, a final polyurethane layer is applied to the decorative layer, on the one hand to protect the decorative layer against Abrich and other mechanical influences and on the other to improve the sound-insulating properties of the floor panel.

Um den Auftrag der abschließenden Polyurethanschicht besonders einfach zu gestalten, kann der Auftrag durch ein Walzendruckwerk erfolgen. Alternativ ist es auch möglich, die abschießende Polyurethanschicht durch Aufgießen und Abrakeln aufzubringen. Es hat sich gezeigt, dass es vorteilhaft ist, die abschließende Polyurethansehicht in mindestens einer oder mehreren Schichten aufzutragen. So kann eine an die jeweiligen Erfordernisse angepasste dicke oder besonders dünne abschließende polyurethanschicht aufgestragen werden. Zwischen dem Aufbringen der einzelnen Polyurethanschichten kann die Trocknung der jeweiligen letzten Polyurethanschicht erfolgen, um den mehrlagigen Aufbau der abschließenden Polyurethanschicht zu ermöglichen und auch besonders dicke Polyurethanschichten zu realisieren, in die besonders tiefe Prägungen eingebracht werden können.In order to make the application of the final polyurethane layer particularly simple, the order can be carried out by a roller printing unit. Alternatively, it is also possible to apply the abschießende polyurethane layer by pouring and doctoring. It has been found to be advantageous to apply the final polyurethane layer in at least one or more layers. Thus, a customized to the respective requirements thick or very thin final polyurethane layer can be embroidered. Between the application of the individual polyurethane layers, the drying of the respective last polyurethane layer can take place to the multilayer structure of the final polyurethane layer to allow and also to realize very thick polyurethane layers, in which particularly deep imprints can be introduced.

Der Trocknungsprozess kann dabei aktiv, zum Beispiel durch ein Heizgebläse, oder auch passiv, zum Beispiel durch Ablüften an der Umgebungsluft, erfolgen.The drying process can be active, for example by a fan heater, or passively, for example by venting in the ambient air done.

Die Aufteilung eines großen Fußbodenpaneels in mehrere einzelne kleine Fußbodenpaneele kann mittels einer mehrerer Aufteilsägen erfolgen. Alternativ sind auch andere Aufteilverfahren, beispielsweise Wasserstrahlschneiden, einsetzbar.The division of a large floor panel in several individual small floor panels can be done by means of a plurality of dividing saws. Alternatively, other distribution methods, such as water jet cutting, can be used.

Optional kann eine weitere Behandlung der Kanten vorgesehen sein. Die Kanten können mindestens teilweise dekoriert werden und/oder eine strukturgebende Prägung erhalten. Vorzugsweise ist die Dekorierung und/oder die strukturgebende Prägung auf das auf der Oberfläche befindliche Dekor angepasst. Dadurch lässt sich der Eindruck einer perfekten Imitation eines natürlichen Werkstoffes noch verstärken.Optionally, a further treatment of the edges may be provided. The edges can be at least partially decorated and / or receive a structuring embossing. Preferably, the decoration and / or the structuring embossing is adapted to the decor located on the surface. This enhances the impression of a perfect imitation of a natural material.

Anhand einer Zeichnung soll ein Ausführungsbeispiel der Erfindung näher erläutert werden. Es zeigt:

Fig.1
- einen Querschnitt des Fußbodenpaneels ;
Fig. 2
- eine Draufsicht auf das Fußbodenpaneel und
Fig. 3
- ein Verfahrensschema zur Herstellung des Fußbodenpaneels.
Reference to a drawing, an embodiment of the invention will be explained in more detail. It shows:
Fig.1
- a cross section of the floor panel;
Fig. 2
- A plan view of the floor panel and
Fig. 3
- A process scheme for the production of the floor panel.

Fig. 1 zeigt den Querschnitt des Fußbodenpaneels mit einer Oberseite 1 und einer Unterseite 2. Auf der Oberseite 1 ist eine Polyurethanschicht 3 als Grundierung und Haftvermittler aufgebracht, auf der Unterseite 2 ist eine Polyurethanschicht 4 als Gegenzug aufgebracht. Auf die Polyurethanschicht 3 ist eine Dekorschicht 5 aufgebracht, die ein einen natürlichen Werkstoff imitierendes Dekor aufweist. Der Auftrag der Polyurethanschichten 3 und 4 erfolgt durch ein Walzendruckwerk 17 und der Auftrag der Dekorschicht 5 auf die Polyurethanschicht 3 erfolgt mit einem Walzwerk 18. Auf die Dekorschicht 5 ist eine abschließende Polyurethanschicht 6 aufgebracht, die dicker ist, als die erste Polyurethanschicht 3 und aus mehreren Schichten besteht. In die Oberfläche der Polyurethanschicht 6 ist eine strukturgebende Prägung 7 mittels eines Walzendruckwerks 17 eingebracht, die einen natürlichen Werkstoff imitiert und an die Struktur der Dekorschicht 5 angepasst ist. Fig. 1 shows the cross section of the floor panel with a top 1 and a bottom 2. On the top 1 a polyurethane layer 3 is applied as primer and adhesion promoter, on the bottom 2, a polyurethane layer 4 is applied as a back-up. On the polyurethane layer 3, a decorative layer 5 is applied, which has a decorating a natural material decor. The order of the polyurethane layers 3 and 4 is carried out by a roller printing unit 17 and the order of the decorative layer 5 on the polyurethane layer 3 is carried out with a rolling mill 18. On the decorative layer 5, a final polyurethane layer 6 is applied, which is thicker than the first polyurethane layer 3 and consists of several layers. In the surface of the polyurethane layer 6, a structure-forming embossment 7 is introduced by means of a roller printing unit 17, which imitates a natural material and is adapted to the structure of the decorative layer 5.

Fig. 2 zeigt die Draufsicht auf die Oberseite 1 des Fußbodenpaneels Auf die erste Polyurethanschicht 3 ist eine Holzmaserung imitierende Dekorschicht 5 und eine abschließende Polyurethanschicht 6 aufgebracht. In die Polyurethanschicht 6 ist eine strukturgebende Prägung 7 eingeprägt ist, die einen natürlichen Werkstoff, hier eine Holzstruktur, imitiert. An den Seitenkanten 10 und 13 sind als Verbindungsmittel Nuten 14 angeformt. An den gegenüberliegenden Seitenkanten 11 und 12 sind als korrespondierende Verbindungsmittel Federn 15 angeformt. Fig. 2 shows the top view of the top 1 of the floor panel on the first polyurethane layer 3, a wood grain imitating decorative layer 5 and a final polyurethane layer 6 is applied. In the polyurethane layer 6, a structuring embossment 7 is embossed, which imitates a natural material, here a wood structure. On the side edges 10 and 13 grooves 14 are formed as connecting means. At the opposite side edges 11 and 12 springs 15 are formed as a corresponding connecting means.

Fig. 3 zeigt eine Vorrichtung zur Herstellung des Fußbodenpaneels. Mittels des Walzendruckwerks 16 wird die eine Polyurethanschicht 4 als Gegenzug zur Verhinderung von Schüsselungen auf die Unterseite 2 des Fußbodenpaneels aufgebracht. Nach dem Trocknen der Polyurethanschicht 4 erfolgt der Auftrag einer Polyurethanschicht 3 als Grundierung und Haftvermittler auf die Oberseite 1 des Fußbodenpaneels mittels des Walzdruckwerks 17. Auf die Polyurethanschicht 4 wird mittels des Walzwerks 18 eine einen natürlichen Werkstoff imitierenden Dekorschicht 5 aufgebracht. Nach der aktiven Trocknung der Dekorschicht mittels der Trocknungsvorrichtung 21 erfolgt der Auftrag der zweiten Polyurethanschicht 5 mittels des Walzendruckwerkes 19. Mittels einer Trocknungsvorrichtung 22 wird die abschließende Polyurethanschicht 6 getrocknet. Zuletzt wird vor der Aushärtung der Polyurethanschicht 6 durch das Prägewerkzeug 20 eine strukturgebende Prägung 7 eingeprägt, um den natürlichen Eindruck des Fußbodenpaneels noch zu verstärken. Fig. 3 shows a device for producing the floor panel. By means of the roller printing unit 16, a polyurethane layer 4 is applied to the bottom 2 of the floor panel as a countermatch to prevent burring. After drying The polyurethane layer 4 is applied to the polyurethane layer 4 by means of the rolling mill 18, a natural material imitating decorative layer 5. After the active drying of the decorative layer by means of the drying device 21, the second polyurethane layer 5 is applied by means of the roller printing unit 19. By means of a drying device 22, the final polyurethane layer 6 is dried. Finally, before the curing of the polyurethane layer 6 by the embossing tool 20, a structure-embossing 7 embossed in order to enhance the natural impression of the floor panel yet.

Bezugszeichenliste:LIST OF REFERENCE NUMBERS

11
Oberseitetop
22
Unterseitebottom
33
Polyurethanschichtpolyurethane layer
44
Polyurethanschichtpolyurethane layer
55
Dekorschichtdecorative layer
66
Polyurethanschichtpolyurethane layer
77
Strukturprägungembossed structure
1010
Kanteedge
1111
Kanteedge
1212
Kanteedge
1313
Kanteedge
1414
Verbindungsmittelconnecting means
1515
Verbindungsmittelconnecting means
1616
WalzendruckwerkRoll printing unit
1717
WalzendruckwerkRoll printing unit
1818
Walzwerkrolling mill
1919
WalzendruckwerkRoll printing unit
2020
Prägewerkzeugembossing tool
2121
Trocknungsvorrichtungdrying device
2222
Trocknungsvorrichtungdrying device

Claims (13)

  1. Floor panel, particularly of wood material, plastic or a mixture of wood material and plastic, with an upper side (1) and an underside (2) and side edges (10, 11, 12, 13), in which panel there is, at least on the upper side (1), an applied polyurethane layer (3) that is elastic to reduce noise when walked on, with a decorative layer (5) applied on top, characterized in that the decorative layer (5) imitates a natural material and there is, on the decorative layer (5), at least one applied polyurethane layer (6), sealing the decorative layer (5), and in that the sealing polyurethane layer (6) has a structured embossing (7).
  2. Floor panel according to Claim 1, characterized in that provided on the underside (2) is a polyurethane layer (4), which contains particles that are heavier than the polyurethane.
  3. Floor panel according to Claim 2, characterized in that the polyurethane layer (4) on the underside (2) contains colour particles.
  4. Floor panel according to Claim 1, characterized in that the decorative layer (5) consists of one or more layers.
  5. Floor panel according to Claim 1, characterized in that the applied amount of the sealing polyurethane layer (6) is 50 to 400 g/m2.
  6. Floor panel according to one or more of the preceding claims, characterized in that corundum particles are incorporated in the sealing polyurethane layer (6).
  7. Floor panel according to one or more of the preceding claims, characterized in that metals or colour particles are incorporated in the sealing polyurethane layer (6) as particles producing an effect.
  8. Floor panel according to one or more of the preceding claims, characterized in that optical brighteners are incorporated in the sealing polyurethane layer (6).
  9. Floor panel according to one or more of the preceding claims, characterized in that antistatically acting particles are incorporated in the sealing polyurethane layer (6).
  10. Floor panel according to one or more of the preceding claims, characterized in that antibacterially acting constituents are incorporated in the sealing polyurethane layer (6).
  11. Floor panel according to one or more of the preceding claims, characterized in that dirt-repelling constituents are incorporated in the sealing polyurethane layer (6).
  12. Floor panel according to Claim 1, characterized in that on the side edges (10, 11, 12, 13) there is an applied decorative layer imitating a natural material.
  13. Floor panel according to Claim 12, characterized in that the decorative layer of the side edges has a structure-giving embossing, imitating the natural material.
EP06017623.7A 2005-09-08 2006-08-24 Building panel having polyurethane layers and a decorative layer Not-in-force EP1762400B2 (en)

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PL06017623T PL1762400T5 (en) 2005-09-08 2006-08-24 Floor panel having polyurethane layers and a decorative layer

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DE102005042657A DE102005042657B4 (en) 2005-09-08 2005-09-08 Building board and method of manufacture

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EP1762400B1 true EP1762400B1 (en) 2012-04-11
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EP1762400A1 (en) 2007-03-14
EP1762400B2 (en) 2015-09-09
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PL1762400T3 (en) 2012-08-31
ES2384880T5 (en) 2016-02-09
US20110059239A1 (en) 2011-03-10
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US8475871B2 (en) 2013-07-02
ATE553271T1 (en) 2012-04-15
PL1762400T5 (en) 2016-07-29

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