EP1934417A1

EP1934417A1 - Floor panel, in particular comprising a ceramic tile

Info

Publication number: EP1934417A1
Application number: EP06793941A
Authority: EP
Inventors: Xavier Bathelier
Original assignee: Tarkett SAS
Current assignee: Tarkett SAS
Priority date: 2005-10-03
Filing date: 2006-10-02
Publication date: 2008-06-25
Anticipated expiration: 2026-10-02
Also published as: EP1934417B1; WO2007039593A1; ES2387820T3

Abstract

A floor panel (10) comprises an external layer (14), for example a ceramic tile placed on a support layer (12). Said support layer comprises a front face oriented towards the external layer and an opposite rear face and is provided with coupling means which are used for interacting with coupling means of a similar panel. The support layer is produced by polymer injection moulding.

Description

FLOOR PANEL, IN PARTICULAR WITH CERAMIC TILE

Technical area

The present invention generally relates to surface covering panels for covering floors, walls or ceilings. It relates more specifically to such panels comprising a ceramic facing.

State of the art

The installation of ceramic tiles and, more generally, of all products made of hard materials such as marble or reconstituted stones based on resin or Portland cement, is today almost universally achieved by gluing directly onto the support (slab concrete or walls) by the use of a suitable glue. These glues are generally of the cement-glue type: Portland cement mixture, filler and latex. These latices, generally entering at a level of 10% in the mixture, are mostly of the styrene-butadiene type and make it possible to considerably improve the adhesion properties of Portland concrete both on the slab and on the tile itself. -even. When the screed is made of wood (or derived product) or if the laying is to be done on an old floor, a grid based on fiberglass or plastic composite is added to enhance the performance of cement glue that will contribute to stabilize the screed and maintain the installation in place.

The mortar thus has the dual function of keeping the tile in position relative to its neighbors and strengthening the ceramic so as to make it more resistant to impact and bending. In this respect, the effectiveness of such glue-cements has become such that in recent years the thickness of ceramic tiles has decreased while their surface area has increased.

This type of pose is well accepted as durable and reassuring. By cons it remains associated with some notable disadvantages: • The pose itself is delicate and tedious. It often requires prior patching. The installation of the joints in fine requires a great thoroughness if one wants a perfect result. So many individuals prefer to entrust the installation to professionals, which more than doubles the amount of investment.

• The installation is installed "for life". Laying a new tiled floor above the previous one is still possible but modifies the threshold levels. This type of operation can not be renewed indefinitely.

• The replacement of a tile in case of breakage, for example following a cracking of the slab, is possible but tedious, and is almost never done in practice.

• The laying of tiles on wood screed or particle board (MDF, fiber cement) is an extremely technical operation that is very little retained by the individual, especially as it has the effect of significantly increase the structure of the building This may be detrimental to a wood-frame building (this type of habitat is widespread in North America and the Nordic countries and will tend to develop in Western Europe as a result of government initiatives related to Kyoto Protocol, because the wood found in the habitat serves as a carbon trap, which contributes to reducing the greenhouse effect In Europe, forests being well managed, the environmental balance is therefore globally positive).

All these considerations mean that the installation of ceramic tiles or similar materials is perceived by the consumer as something that must be final and that corresponds to a significant investment (especially if the installation is entrusted to a professional), which encourages him to turn to products perceived as quality (so even more expensive) and fairly neutral aspect (if the building must be sold, the new buyer should not be slowed by the appearance of coatings.) This has to a corollary of limiting the offer from the aesthetic point of view, essentially with regard to ceramics: the vast majority of products ceramics have a neutral appearance or imitation stone (more recently wood imitations), that is to say, have aspects considered timeless, while sophisticated techniques based on enamels exist and would allow very rich and more "trendy" decorations. Sensitive to these problems, manufacturers have tried to provide an answer by combining ceramics support layers in HDF, MDF or other agglomerates based on wood fibers.

WO 2004/097141 proposes for example a floor covering panel comprising a wooden support layer of generally rectangular shape, on the front face of which are fixed by gluing, two ceramic tiles. The edges of the wooden support are machined to obtain profiles allowing their interlocking according to the well-known principles of so-called "floating" parquet.

This type of panel does not totally eliminate the disadvantages listed above and even creates new problems. Indeed, such panels do not provide complete satisfaction because the joint must be realized in a conventional manner. As a result, the installation is not really removable. Wood-fiber panels, even when treated, remain sensitive to moisture, which in the long run will cause level variations and joint openings. In addition, it is still not possible to easily replace a damaged tile.

General description of the invention

The present invention results from the observation of the disadvantages of the solutions of the state of the art in the field of flooring panels, especially those with ceramic facing, and aims to provide an advantageous alternative particularly designed for this type of products.

According to a first aspect of the present invention there is provided a method of manufacturing a surface coating panel comprising an outer (or decorative) layer on a support layer. The support layer has a front face facing the outer layer and an opposite rear face, and presents coupling means. According to an important aspect of the invention, the support layer is manufactured by polymer injection molding.

It will be appreciated that the choice of the polymer injection molding technique for producing the support layer has many advantages. This makes it possible to produce a support with the chosen dimensions and to simultaneously form the coupling means. In this way, a "finished" support is obtained in a much simpler, faster and more economical way than with MDF or HDF support layers which require, in addition to the initial manufacture of the boards, a cut to size and a machining of the fields. In addition, injection molding allows great flexibility in the choice of shapes, whether the general shape of the panel itself, or the shape of the coupling means.

The method according to the invention is particularly well suited, but not limited, to the manufacture of surface coating panels of the type comprising a decorative outer layer (or facing) of hard material such as ceramic, rock or stone. , especially in the form of tile (x). Such panels thus allow a floating installation of tiles.

In the more specific context of application to floating tiles, the use of polymer for the support layer makes it possible to take advantage of the range of mechanical properties of the polymers for reinforcing the ceramic outer layer, and thus to improve the flexural strength and impact resistance of ceramic tile. In addition, it will be appreciated that injection molding advantageously provides a rear face of the backing layer with a backing structure for increasing flexural and impact strength. Such a reinforcing structure comprises for example reinforcing ribs and / or recessed areas. Preferably, the rear face of the support layer is molded so as to have a network of ribs forming a wall structure.

It should be noted that the recessed areas between the ribs and walls lead to a lightening of the support, and therefore overall weight of the panel, which is also appreciable for the user during installation. We can achieve a halving of the density compared to a support layer in HDF.

If the process according to the invention was initially developed for the production of panels with a decorative layer made of tile (x) of ceramics or stones, various types of materials can nevertheless be envisaged for the top layer: wood, polymers, glass , enamel, melamine decorations or even metal sheets. In addition, the outer layer itself may consist of several superimposed and / or adjacent layers. It will thus be possible to produce floor coverings, walls or ceilings with various aspects. The outer layer is preferably securely bonded to the support layer.

According to a first embodiment of the method, once the support layer obtained by injection molding, the outer layer is placed in place on the latter, preferably by means of an adhesive (film or glue). In the case where the outer layer consists for example of a single ceramic tile, it is sufficient to apply the adhesive (on the front face of the support and / or the rear face of the tile), then to put them in contact . If the outer layer consists of several tiles, we can:

- Or form the outer layer on the front face of the support by laying (and adhesive) the tiles one after the other;

- Or make a pre-assembled outer layer by putting (and adhesive) the tiles on an auxiliary support, then stick the pre-assembled outer layer on the front of the support.

According to a preferred embodiment, the connection between the outer layer and the support layer is during the injection molding of the latter. The outer layer, e.g. one (or more) ceramic tile, in the bottom of the injection mold before the introduction of the polymer. The support layer is then molded in direct contact with the rear face of the outer layer. Depending on the nature of the outer layer and the type of polymer used for the support, it is thus possible to directly obtain the adhesion between the front face of the support and the outer layer. employment a thermoplastic or hot-melt adhesive film at the decor / support interface (eg placed on the back side of the decorative outer layer in the injection mold) allows more precise control of the bond between the layer outside and the support layer. When the connection between the outer layer and the support layer is thus made, it is of course understood that the material of the outer layer withstands the temperatures during the injection cycle, which is naturally the case for ceramics. This variant of the process according to the invention makes it possible to obtain in a single step the finished product, ready for use. Many polymers are compatible with the injection molding technique, whether loaded or not. For applications in the production of panels with a ceramic outer layer, it will be possible to choose polymers that impart good shock absorption. Depending on the use envisaged for the panel, it may be advantageous to use polymers which are not very sensitive to humidity.

When the polymer is injected in contact with the ceramic, the injected material is advantageously formulated to be made compatible with the ceramic and cause a slight shrinkage. The tensions generated by this low shrinkage will be collected by the ceramics (work essentially compres- sion so easily bearable) which will allow the respect of the dimensions of the reinforcement piece. Polypropylene is particularly preferred for the support layer.

As mentioned above, injection molding allows great flexibility in the choice of shapes, especially with regard to the coupling means. In the field of floors and so-called "floating floors", many coupling systems between adjacent panels have been proposed, and can naturally be transposed to the panel according to the invention. In particular, the coupling means may be designed to allow a tongue and groove type interlocking. In this case, as we know, the grooves and tongues may comprise a mechanical locking system in the transverse direction, and / or be designed for angular interlocking (with or without "click").

Alternatively, the coupling means may be designed to cooperate with separate coupling elements.

According to another aspect of the present invention, there is also provided a surface coating panel, particularly of floor, comprising an outer layer on a support layer, the support layer having a front face facing said outer layer and an opposite rear face, and having coupling means adapted to cooperate with the coupling means of a panel of the same type. According to the invention, the support layer is injection molded polymer.

As explained above, the injection molding technique makes it possible to manufacture the support layer simply and quickly, including with complex shapes of the panel and coupling means. In addition, when the outer layer is placed in the mold to be joined to the support layer during the molding thereof, there is obtained in a single step of manufacture a ready-to-use panel, thus comprising a decorative outer layer, a support layer with its coupling means, and preferably a reinforcing structure.

In a particularly preferred variant of the invention, the outer layer comprises one or more tiles (x) of hard material, such as for example ceramic, rock or stone. Rectangular tiles are in practice the easiest to use for reasons of symmetry, one can nevertheless consider a variety of forms.

The use of a plastic support is particularly advantageous in this application with an outer layer of ceramic tiles or other hard materials, because the use of a plastic support layer to which the (or the) tile is firmly bonded (x) strengthens the ceramic to achieve sufficient values of flexural strength and impact resistance compatible with domestic use. Increased reinforcement can be advantageously obtained by playing on the design of the rear face of the support layer, and in particular by realizing a structure of reinforcement with ribs and recesses.

Such a panel with ceramic outer layer thus makes it possible to produce tiled surfaces in floating laying, and constitutes a very interesting alternative for the realization of tiled surfaces: - the laying is easy for a particular and no longer requires the use of cement glue nor the use of a professional;

- damaged panels can be removed individually and replaced easily (since they are not glued to the ground);

- in case of moving, wearing, or simply if you want to change the coating, the coating can be completely disassembled and the new coating installed, without changing the level;

- The installation can be performed over a wooden screed (or derivative) and on old coatings difficult to remove such floors or textile glued, or even directly on concrete. An important aspect in making a tile is the presence of joints between adjacent tiles to seal the surface. In order to maintain a spirit consistent with the floating pose, the present invention provides the use of resilient seals designed to fill the gap separating two adjacent panels. Where appropriate, these elastic seals may comprise recessed portions for the coupling means connecting the adjacent panels.

The seals can be separate elements. However, according to a preferred variant, the panel according to the invention comprises at least one peripheral seal (in a softer polymer, eg in flexible pvc) which is injected in contact with the support layer, for example using the technique bi-injection.

According to a preferred variant, a separate coupling means in the form of a plastic profile comprises at least two coupling portions to be able to join two panels of this type. The coupling means then comprise corresponding housings intended to cooperate with the shaped coupling portions. These housings are preferably located in the rear face of the support layer.

In order to improve the strength of the coupling, each separate coupling element is advantageously provided with first locking means which cooperate with second locking means in the walls of the corresponding housings in the support layer. To do this, one can use a system type lugs / notches that will engage in force in each other during the establishment of profiles in the housing.

According to a third aspect of the present invention, there is provided a construction kit comprising panels as defined above, separate coupling elements adapted to cooperate with the coupling means of at least two of these panels to couple them in a assembly plan. If the panels are not provided with peripheral seals, the kit advantageously comprises separate seals able to be inserted between the gap separating two adjacent panels.

Description of the drawings

Other features and characteristics of the invention will become apparent from the detailed description of some advantageous embodiments presented below, by way of illustration, with reference to the accompanying drawings. These show: FIG. 1: a simplified perspective view of a preferred embodiment of a panel according to the invention;

FIG. 2: a view from below of the panel of FIG.

FIG. 3 is a perspective view of a coupling element for coupling the panel of FIG. 1 to adjacent panels; FIG. 4: a bottom view of a panel assembly;

FiG.5 and 6: views of details A and B respectively illustrating a lug on the inner wall of a wall defining a housing and a corresponding notch in the coupling section; and FIG. 7 is a perspective view of a separate seal. In the figures, the same reference signs designate identical or similar elements.

Detailed Description of Some Preferred Embodiments

The present invention relates to a surface coating panel comprising a decorative outer layer associated with an injection molded support, and a method of manufacturing such a panel.

In the preferred variant illustrated in FIG. 1, there is provided a floor covering panel 10 comprising a lower layer called a support layer 12 and an upper or outer layer 14, comprising a front face 16 facing the outer layer 14 and a face rear 18 opposite. The outer layer, which is the decorative layer of the panel, is a ceramic tile (or other hard material type stone or rock).

It will be appreciated that the support layer 12, which includes coupling means (not shown in Fig.1) for joining the panel 10 to other panels of the same type, is obtained by polymer injection molding. Injection molding makes it possible to directly obtain a support 12 of the desired dimensions and with coupling means; subsequent operations of cutting the support and machining of the coupling means are no longer necessary. In addition, the molding allows a wide variety of forms of the support (and therefore the panel) and the coupling means. It will further be appreciated that the rear face 18 of the support 12 advantageously has a reinforcing structure which is intended to strengthen the ceramic to achieve shock resistance to shocks compatible with domestic use. Such a reinforcement structure typically comprises ribs 20 and recessed areas 22, and allows for example the realization of a wall structure as shown in Fig.2.

It will be understood that for effective strengthening of the ceramic 14, it is desirable that the latter is securely assembled to the support 12. According to the present method of manufacture, there are several ways to assemble the ceramic tile to its support: a) By gluing. An adhesive adapted to the polymer used is deposited for example by "coating" on the support. This mode makes it possible to overcome the dimensional problems related either to the ceramic itself or to the support which can undergo a random withdrawal after cooling. b) During the injection itself by direct contact between the ceramic and the molten polymer introduced under pressure. In this case, the calibrated ceramic tile can be introduced into the bottom of the mold before the start of the injection cycle. The injected material is advantageously formulated to be made compatible with the ceramic and cause a slight shrinkage. The tensions generated by this low shrinkage will be cashed by the ceramic (working essentially in compression therefore easily bearable) which will allow the respect of the dimensions of the reinforcement piece. c) During the injection by adding a film after the introduction of the ceramic. This film (for example a melamine film) merges at the time of injection of the hot polymer and provides the interface between the polymer constituting the reinforcing piece and the ceramic. It is of course chosen for its compatibility with both materials.

Modes b) and c) will be preferred since they avoid the additional step of bonding mode a), and thus make it possible to obtain the finished product directly. Modes b) and c) are easy to implement. It suffices simply to arrange in the mold of the support 12 a space for the (or) tile (x) ceramic 14.

As mentioned above, injection molding allows a great diversity in the realization of the coupling means. It is naturally possible to provide tongue and groove type coupling, optionally with or without angular engagement. Such couplings are well known in the field of floating floors.

The coupling between the panel 10 and the adjacent panels 10 'and 10 "is preferably made by means of coupling elements in the form of a coupling section 24 as illustrated in FIG. profile form the coupling portions 26 and 28 which are adapted to cooperate with housings 30 (of corresponding shape) provided in the rear face 18 of the support layer 12. In the present variant, the housings 30 for the coupling portions are defined by the ribs 20 (walls) of the reinforcement structure.

4 shows a bottom view of the assembly of the panel 10 with two adjacent panels 10 'and 10 "The panel 10 is connected to each adjacent panel by a pair of profiles 24 whose coupling portions 26 and 28 The profiles 24 also determine the inter-panel spacing 10, 10 ', respectively 10, 10 ".

Advantageously, locking means with pins and notches are provided to block the profiles 24 in the housings 30. As can be seen in FIG. 2, and in more detail in FIG. 5, the interior walls of the walls defining the housings 30 are provided with lugs 32. When the profiles are interlocked in the respective housings of the panels to be connected, the lugs 32 on the walls engage in corresponding notches 34 of the profiles (see FIG. 6). These lugs are distributed in such a way that their engagement in the notches is made in force thanks to the flexibility of the walls.

The coupling section 24 may also be made by polymer injection molding. A more elastic polymer than that constituting the support layer will preferably be used.

Referring again to Fig.1, note the presence of a peripheral seal 36 extending over the entire length of the edge. It is advantageously produced by the bi-injection technique, after the injection of the support 12 and in direct contact with it. The seal 36 is made of flexible polymer, e.g. soft PVC.

The seal 36 is sized to fill the inter-panel gaps

10, 10 ', resp. 10, 10 ", although only one seal 36 is shown in Fig. 1, it can be provided along each edge, the thickness of the seal 36 can correspond to the total distance between the panels. if the four songs have joints, we can size them so that their thickness is slightly greater than half of the gap inter-chants. Thus, the joints of each of the panels contribute to fill the interstices.

Of course, the joints can be made separately, and put in place in the interstices after assembly of the panels. Such a separate seal 38 is shown in Fig.7; its thickness is such that it fills the interpanneaux gap.

Whether the joints are separated or integral with the panels, if coupling elements such as the profile 24 are used, it is advantageous to provide recesses in the lower part of the joints for the passage of the profiles (see recess 40). in the lower part of the joint 38, Fig.7).

The present invention therefore also relates to a building kit comprising panels 10 as described above and profiles 24. If the joints are not preformed on the panels, the kit will comprise in others a plurality of separate joints. Starting from this construction kit, it will be left to the user to fit the profiles 24 in the housing provided for this purpose in the support 12 to achieve a surface coating whose appearance will match perfectly to that a traditional tile laying.

Any panel can be removed and / or replaced by inserting a screw-type tool between the seal and the adjacent panel and then exerting a lever effect to separate the profile of its housing under the support.

In the case where the seal is not formed on the support by bi-injection but made apart, the installation is also very simple. After assembling the panels using the profiles, the joints are pushed between the tiles above the profiles.

Example 1 - resistance tests

A panel comprising a 20x20 cm porcelain stoneware ceramic tile was made on a polypropylene support piece having a rear face with a reinforcing structure as illustrated in FIG. The support piece was formed directly in contact with the placed ceramic in the mold.

The ceramic had a Young's modulus of 3.7x10 ⁵ Mpa and a fish coefficient of 0.22. Polypropylene was standard with a Young's modulus of 30 MPa and a fish coefficient of 0.4. This panel has been submitted:

a flexural strength test by applying stresses of the order of 3 000 N distributed uniformly over the ceramic.

- to local stresses called "foot of chair" applied on 2 cm ² for a value of 1300 N. No cracks or cracks were observed on the ceramic tile.

Example 2 - Manufacturing Example

A calibrated ceramic tile between 3 mm and 6 mm thick is deposited at the bottom of the mold of a bi-injection press, the decoration face of the ceramic against the bottom of the mold.

A first polypropylene injection at 210 ^° C. containing 5% by weight of fiberglass is carried out directly on the ceramic (against the non-decorative back side thereof) using a rotating mold. The first imprint of this mold corresponds to the support layer.

After 2 mm of cooling a second injection takes place using a second impression (after rotation of the mold) corresponding to the seal. This seal is positioned for example square against the support and is based on flexible PVC. The fact that this injection takes place while the support layer is still hot guarantees good adhesion between the polymers.

After another two minutes, the complete part is ejected and a new cycle can resume.

The shrinkage of the polypropylene filled with fiberglass is low enough not to cause major deformation of the support (the ceramic playing as a stabilizing element.) once cooled the support will be able to play its role fully by improving the resistance to impact and bending of the ceramic while the ceramic plays the role of stabilizer support, thus ensuring its dimensions (in relation to the dimensions of the coupling profiles) during its cooling. In this application, it will preferably be chosen for the support a polymer whose shrinkage is not excessive (<0.5%), in order to limit the shear stresses that could separate the ceramic from the support layer.

Claims

claims

1. A surface coating panel, particularly of ground, comprising an outer layer on a support layer, said support layer having a front face facing said outer layer and an opposite rear face and having coupling means adapted to cooperate with the coupling means of a panel of the same type, characterized in that said support layer is injection molded polymer.

2. Panel according to claim 1, wherein said outer layer is firmly bonded to the support layer.

3. Panel according to claim 1 or 2, wherein said support layer is firmly bonded to the outer layer by means of an adhesive.

4. Panel according to claim 1, 2 or 3, wherein the rear face of the support layer has a reinforcing structure comprising ribs and / or recesses.

5. Panel according to any one of the preceding claims, wherein the outer layer comprises at least one tile in a hard material such as ceramic, stone or rock.

The panel of any one of the preceding claims comprising one or more peripheral injection molded polymer seals.

A panel as claimed in any one of the preceding claims, wherein said coupling means is provided at the edges of the panel and adapted for tongue and groove interlocking coupling.

8. Panel according to any one of claims 1 to 6, wherein said coupling means are adapted to cooperate with a separate coupling element, which is designed to cooperate with the coupling means of at least one other sign.

9. Panel according to claim 8, wherein said separate coupling member is a plastic profile comprising at least two coupling portions for joining two panels of this type; and said coupling means comprise corresponding housings adapted to receive said coupling portions of said profile.

10. Panel according to claim 9, wherein said housings are located in the rear face of the support layer.

The panel of claim 9 or 10, wherein said separate coupling member is provided with first latch means which cooperates with second latch means in the walls of corresponding housings in the support layer.

Floor covering comprising a plurality of panels according to any one of the preceding claims coupled together.

A building kit comprising: panels according to any one of claims 1 to 11; separate coupling elements adapted to cooperate with the coupling means of at least two of these panels to couple them in an assembly plane.

14. Building kit according to claim 13, comprising separate joints adapted to be inserted into the gap separating two adjacent panels.

15. Building kit according to claim 13, wherein the panels are provided on at least one of their edges, a polymer peripheral seal.

16. A method of manufacturing a surface coating panel, particularly of the floor, said panel being made to comprise an outer layer and a support layer, said support layer having coupling means for cooperating with means for coupling a panel of the same type, characterized in that said support layer is formed by polymer injection molding.

17. The method of claim 16, wherein the molding of the support layer is made so that it has a back face with a reinforcing structure.

18. The method of claim 17, wherein said reinforcing structure comprises reinforcing ribs and / or recesses.

19. The method of claim 17 or 18, wherein the outer layer is associated with the support layer during molding thereof.

The method of claim 19, wherein the support layer is injection molded into contact with at least a portion of the rear face of the outer layer.

The method of claim 19, wherein the back side of the outer layer is coated with an adhesive layer, and the backing layer is injection molded against the back side of the outer layer.

22. The method of claim 17 or 18, wherein the outer layer is associated with the support layer after demolding and cooling.

23. A method according to any one of claims 17 to 22, wherein the outer layer comprises at least one tile of hard material such as ceramic, stone or rock.