EP2694300A1 - Revêtement de sol et procédé de fabrication de ce revêtement - Google Patents

Revêtement de sol et procédé de fabrication de ce revêtement

Info

Publication number
EP2694300A1
EP2694300A1 EP12727246.6A EP12727246A EP2694300A1 EP 2694300 A1 EP2694300 A1 EP 2694300A1 EP 12727246 A EP12727246 A EP 12727246A EP 2694300 A1 EP2694300 A1 EP 2694300A1
Authority
EP
European Patent Office
Prior art keywords
layer
floor panel
carrier layer
decorative
binder
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.)
Granted
Application number
EP12727246.6A
Other languages
German (de)
English (en)
Other versions
EP2694300B1 (fr
Inventor
Guido Schulte
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.)
Individual
Original Assignee
Individual
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 Individual filed Critical Individual
Publication of EP2694300A1 publication Critical patent/EP2694300A1/fr
Application granted granted Critical
Publication of EP2694300B1 publication Critical patent/EP2694300B1/fr
Active legal-status Critical Current
Anticipated expiration legal-status Critical

Links

Classifications

    • 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
    • B44C5/0469—Ornamental plaques, e.g. decorative panels, decorative veneers comprising a decorative sheet and a core formed by one or more resin impregnated sheets of paper
    • B44C5/0476—Ornamental plaques, e.g. decorative panels, decorative veneers comprising a decorative sheet and a core formed by one or more resin impregnated sheets of paper with abrasion resistant properties
    • 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
    • E04F15/107—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 composed of several layers, e.g. sandwich panels

Definitions

  • the invention relates to a floor panel, which has a carrier layer, wherein above the carrier layer, a decorative layer and an overlay are arranged, and a method for producing a floor panel.
  • a laminate floor paneling consists of a carrier plate made of fiber material, usually a high- or medium-density fiberboard, on top of which a decorative layer, for example a resinated decor paper, is applied.
  • the decorative layer determines the appearance of the laminate.
  • overlay or the seal forms a special treated wear layer of paint, which gives the floor panel a high surface durability.
  • a return can be applied on the underside of the carrier layer. This serves the dimensional stability and the moisture barrier.
  • a footfall sound insulation may also be provided on the underside.
  • a laminate floor consists of several rows of rectangular floor panels in their configuration.
  • the bottom panel On one longitudinal side and one head side, the bottom panel usually has continuous grooves and, on the respectively opposite longitudinal side or head side, continuous springs which are adapted in a form-fitting manner to the grooves.
  • the floor panel of two adjacent rows is arranged offset from one another.
  • the carrier layer consists of a compressed fiberboard.
  • the fiberboard are very suitable for the purpose. They have the necessary stability, are easy to work with and cost-effective. High density and medium density fiberboards, however, are relatively rigid and stiff and do not conform to the subfloor. There is no thermoplastic flow. This is often good, but sometimes also disadvantageous, especially if a certain elasticity of the floor covering would be desirable due to the laying situation or the substructure.
  • the carrier layer there referred to as the core, made of soft PVC.
  • a decorative film On top of the carrier layer is a decorative film provided, which is printed with a decor.
  • a transparent wear layer is applied, which also consists of PVC.
  • DE 10 2009 000 717 A1 also includes a natural / synthetic sheet material which can be used inter alia for the production of floor coverings.
  • a natural / synthetic sheet material which can be used inter alia for the production of floor coverings.
  • a floor panel which has a carrier layer, wherein a decorative layer and an overlay are arranged above the carrier layer.
  • the carrier layer is formed on the basis of a mineral material and a binder.
  • DE, 19944 399 A1 also discloses a floor panel which has a carrier layer which is formed on the basis of a mineral material and a binder. Above the carrier layer, a decorative layer and an overlay is arranged.
  • a hard floor floor covering belongs to the prior art with an insulating profile of crosslinked natural and / or synthetic latex arranged on the underside.
  • the support layer consists of a biomaterial-plastic composite material. In the carrier layer cavities may be formed.
  • EP 0 081 147 B1 discloses a building panel consisting of a pressed core of wood particles surrounded by thermoset phenol-formaldehyde resin.
  • a decorative layer is arranged, which may consist of a fabric, nonwoven fabric, a plastic, paper or wood foil and / or a lacquer layer.
  • EP 1 985 464 A1 includes a prior art floor panel comprising a core consisting of at least one upper layer and a lower layer of glued wood fibers or wood shavings glued together with an adhesive. At least the fibers or chips of the top layer are glued with an adhesive having thermoplastic properties.
  • the carrier layer is provided with a decoration that is covered with a sealing layer. In the sealing layer, a corresponding to the decor surface structure is imprinted. The upper layer has depressions formed at least immediately under the decoration.
  • the invention is based on the prior art, the task of creating a floor covering that is environmentally friendly and manages without PVC or the use of plasticizers and isocyanates and has good performance properties. It is a further object of the invention to provide a method for producing a floor panel.
  • the carrier layer of the floor panel is formed on the basis of a mineral material and a binder.
  • the mineral material is mixed in powder or granular form with the binder and formed into a carrier layer.
  • the mineral material is free of environmental or health-damaging ingredients. The same applies to the binder.
  • the floor panel has a high environmental friendliness.
  • a nonwoven layer is applied to the carrier layer.
  • the decorative layer is then preferably formed by a decor printed on the nonwoven layer decor.
  • the Viies Mrs can be provided with a primer before printing.
  • This embodiment is particularly advantageous in terms of impact resistance and elasticity of the floor panel.
  • the fleece also acts as a reinforcement and can for special Properties are modified, for example in the antistatic effect. Kevlar or carbon fiber nonwovens can also be used as fleece.
  • the carrier layer is PVC- and plasticizer-free, furthermore free of isocyanates.
  • the mineral material ensures a high impression resistance. By choosing the binder, the panel stiffness can be adjusted.
  • the carrier layer can be processed with modern milling and profiling tools and configured for specific applications.
  • the floor panel of the invention consists of the opposite fiberboard or gypsum boards more elastic, less brittle mineral support layer, which is provided on the upper side with a decor and a wear layer.
  • the decor or decorative layer is preferably a nonwoven, in particular a printed nonwoven, the wear layer is preferably made of aminoplastic resins.
  • the binder of the carrier layer is formulated such that it gives the carrier layer and thus the bottom panel a purpose-optimized elasticity.
  • the floor panel is insensitive to water. By combining the materials and the mixing ratio of the carrier layer and the synergistic interaction with the structure of the decorative layer and the wear layer, the floor panel is adjustable in terms of elasticity and deformation properties and water absorption / swelling. Particular importance is attached to the nature of the binder and the amount of binder.
  • the carrier layer contains at least 50% by volume of the mineral material.
  • the carrier layer has from 70% by volume to 100% by volume, preferably from 75% by volume to 90% by volume, of mineral material content.
  • the mineral material used is preferably gypsum, limestone or dolomite or a mixture of the abovementioned minerals.
  • the binder content in the carrier layer is greater (>) 10% by volume.
  • the binder content is preferably between 18% by volume and 28% by volume, in particular between 20% by volume and 25% by volume.
  • the binder or binder content is matched to the grain size and grain distribution of the mineral materials and in particular with regard to the desired properties, which should have the floor panel.
  • the binder is a water-based acrylate resin.
  • This is a purely water-based and formaldehyde-free acrylate resin, which is environmentally friendly and brings very good binding properties for the production of carrier layers according to the invention.
  • Another advantageous binder is a polymeric binder, in particular a binder based on vinyl acetate and ethylene copolymers.
  • a biopolymer or a polymer blend is very suitable as a binder.
  • biodegradable polymeric binders are used. This also lends itself in practice to the use of polymer blends, which are a mixture of synthetic and natural polymers.
  • Main component of the polymer blend is a natural polymer of a renewable raw material, such as starch, in a proportion of at least 65%.
  • the carrier layer has a basis weight of greater than or equal to (>) 3.0 kg / m 2 .
  • This relatively high mass occupancy (often referred to as basis weight) ensures a good lying behavior of the floor panel.
  • the choice and the composition of the binder gives the carrier layer and thus the entire floor panel a plastoelastic lying behavior, which counteracts stresses from the overlay or the seal and minimizes or even eliminates distortion phenomena.
  • the preparation of components for the carrier layer can be effected by extrusion.
  • the mineral material and the binder in formed an extruder into pellets or granules and then processed these granular substances for Rajschtcht. This is preferably done on a continuous belt press, a so-called Thermomeltstrom. In principle, however, this is also possible on a CPL (Continuous Pressure Laminate) system or the like.
  • the extrudate production of the carrier layer is used in particular in polymeric binders, in particular in a binder in the form of vinyl acetates.
  • acrylate binders these are admixed with the mineral material and this mixture is then shaped into a carrier layer, for example by applying the pasty, spreadable mixture to a belt system, configuring it and drying it.
  • the carrier layer can contain additives, in particular biological additives, in a proportion of less than ( ⁇ ) 50% by volume. This is particularly intended to the use of aggregates in the form of cork or leather granules and similar biological additives. Also rubber or natural rubber are suitable as an additive
  • the specific weight of the carrier layer is between 1.5 kg / m 3 and 2.5 kg / m 3 , in particular about 2.0 kg / m 3 .
  • the practical application of the floor panel according to the invention is improved in that the side edges of the floor panel are profiled and provided with locking means in the manner of a click system.
  • the carrier layer of mineral material has a very good profiling.
  • the carrier layer can be processed very well with modern milling and Profilierwerkmaschineen and provided at their side edges with a corresponding profiling including locking means.
  • the decorative layer may consist of a printed decorative paper.
  • a decorative layer of decorative paper is relatively inexpensive.
  • An advantageous aspect of the invention is to print the decorative layer directly, optionally after prior application of a primer, onto the surface of the carrier layer, in particular in digital printing or inkjet processes.
  • the preparation of the carrier layer for a direct application of the decorative layer to the carrier layer may comprise a fine grinding, an application of a primer and / or a printing base.
  • the printing itself can, as mentioned, be done by means of indirect gravure printing or non-contact digital. These panels also have the advantage of a rational and rapid production with low production costs.
  • the floor panel is provided with an overlay on the upper side.
  • the overlay is formed on one or more layers and consists of transparent paints and / or transparent resins with optionally wear-increasing additives such as corundum.
  • the incorporation of effect particles into the overlay is also possible.
  • the floor panel below or above the carrier layer can be provided with a stabilizing fabric.
  • a multi-layer body is produced.
  • the multilayer body comprises a carrier layer based on a mineral material and at least one decorative layer and an overlay.
  • a nonwoven layer can be arranged between the carrier layer and the decorative layer.
  • the decorative layer can also be formed by a nonwoven layer printed with a décor.
  • the multilayer body is fed to a press and the layers of the multilayer body are pressed together under pressure and temperature in the press.
  • the pressing process is preferably carried out at a temperature between 120 ° C and 200 ° C.
  • the pressure during the pressing process is between 1,500 kPa and 6,000 kPa.
  • the carrier layer of mineral material which is bound by a biological binder, is at least partially or partially elasticized during the pressing process. This increases the connection with the remaining layers of the floor panel. This is particularly advantageous in order to give structures to the floor panel despite a thin overlay. In this case, deeper structures than previously usual can be generated.
  • the surface structures are pressed into the floor panel or its surface in the manner of a grain and gloss levels.
  • the overlay or the resin, which forms the overlay during the pressing process set flexible, so that the resin during the compression is flowable, distributed like a film and then cured.
  • the decorative layer and / or the nonwoven layer can also be applied to the carrier layer if the carrier layer has not yet completely cured.
  • the production of the carrier layer is involved in this process in the process of manufacturing the floor panel.
  • the mineral materials and the binder are mixed and preferably into large-sized plates, for example in the dimensions of 2.10 m x 2.60 m in a thickness of 4 mm to 12 mm, preferably 5 mm to 6 mm formed.
  • the further layers ie at least the decorative layer, if appropriate the nonwoven layer and the overlay, are applied to the carrier layer and this multilayer structure is then pressed.
  • the carrier layer of mineral material bound by the binder can also be used completely cured for producing a floor panel according to the invention.
  • the further layers are then optionally applied with the addition of fixatives and / or adhesives in the layer structure.
  • the nonwoven fabric is a textile fabric of individual fibers or filaments.
  • the nonwoven layer can be formed, for example, from a glass fleece or polyester. Basically, a combination of glass and polyester is possible.
  • the nonwoven layer may further be made of polyamide or polyethylene terephthalate (abbreviation PET). In addition, a combination of polyamide and polyethylene terephthalate is conceivable.
  • the nonwoven may also contain fibers of different strength, in particular stiffening fibers of Kevlar or carbon may be incorporated into the nonwoven.
  • the nonwoven layer is characterized by a high strength and stability.
  • the nonwoven layer is particularly well suited for receiving the decor.
  • the nonwoven layer consists of endlessly spun filaments, which are processed without solvent and binder to the nonwoven layer.
  • FIGS. 1 to 5 show five different embodiments of a floor panel 1, 2, 3, 4 and 5 according to the invention.
  • Each floor panel 1-5 comprises a carrier layer 6, a decorative layer 7 arranged above the carrier layer 6 and an overlay 8.
  • the carrier layer 6 is formed on the basis of a mineral material and a binder, wherein the carrier layer 6 contains at least 50 vol .-% of the mineral material.
  • the mineral material consists of carbonates such as limestone or dolomite.
  • the mineral material may be wholly or partially made of calcium sulfate, namely gypsum, or even from Anhydride exist. A mixture of the aforementioned minerals is possible.
  • the mineral material is bound by a formaldehyde-free, PVC-free and plasticizer-free binder.
  • the binder may be a water-based acrylate resin.
  • a polymeric binder in particular a binder based on vinyl acetate and ethylene copolymers or a biopolymer or a polymer blend, can be used to bond the mineral material.
  • the mineral material is added in powder form and / or in granulated form with addition of liquid with the binder and formed into a carrier layer.
  • the carrier layer has a basis weight of greater than or equal to (>) 3.0 kg / m 2 . It is possible to incorporate biogenic aggregates such as cork, leather granules and similar natural products into the carrier layer in a proportion which is less than 50% by volume.
  • the side edges 9, 10 of the floor panel 1 - 5 are profiled and provided with locking means 11.
  • the profiling is formed on the carrier layer 6 and comprises at the bottom panel 1 - 4 at a first side edge 9 one of two springs 12, 13 limited first groove 14 and at a second set edge 10 a likewise limited by two springs 15, 16 second groove 17th
  • the first groove 14 is formed in a circular section at least in the upper peripheral region 19 adjacent to the upper side of the panel 18 and opens into the first side edge 9 by way of a rounded bead 21 facing the lower panel 20 on the upper first spring 12 bounding the first groove 14 has at least one adapted to the troughed peripheral portion 19 of the first groove 14 upper spherical surface portion 22 and has a top of the second groove 17 forming, provided subsequent to a rounded lower front portion 23 lower insertion slope 24. This corresponds in terms of their inclination angle Inclination angle of the top of the first side edge 9 offset from the front side rounded second spring 13th
  • the carrier layer 6 has strip-like locking means 11.
  • a continuous coupling groove 25 are provided with a bottom-projecting limited resilient latching tongue 26 on the first side edge 9.
  • the locking means 11 is formed by a projecting clutch spring 28.
  • the coupling groove 25 and the clutch spring 28 are contour matched so that they engage in the laying of the floor panel 5 in a floor covering adjacent floor panel 5 latching.
  • the clutch springs 28 engage in the coupling grooves 25.
  • the latching tongue 26 slides under the clutch springs 28, wherein the rib 27 engages in the latching groove 29. In this way, the bottom panel 5 along its side edges 10, 11 gap-free and glueless tensile and pressure resistant be added.
  • cavities 30 are provided in the carrier layer 6.
  • the cavities 30 shown here are embedded within the carrier layer 6 and closed circumferentially. Basically, slot or channel-side cavities may be provided which are open on one side and open into the top or bottom of the carrier layer.
  • the decorative layer 7 may be a printed decorative paper.
  • the decorative layer 7 is printed by printing on the upper side 31 of the carrier layer 6 (FIG. 1).
  • a primer has been applied to the top 31 prior to printing the decorative layer 7.
  • a nonwoven layer 32 is applied on the carrier layer 6.
  • a nonwoven layer 32 is applied to the carrier layer 6.
  • the decorative layer 7 is preferably printed digitally on the nonwoven layer 32.
  • the overlay 8 forms both the bottom panel 1 and the bottom panel 2 - 5, the top or side seal and consists of transparent paints and / or transparent resins, which may be applied in one or more layers.
  • a stabilizing fabric 33 is applied on the underside of the floor panel 3.
  • the floor panel 4 in the embodiment of Figure 4 comprises a stabilizing fabric 34 incorporated between the nonwoven layer 32 and the support layer 6.
  • the stabilizing fabric 34 as well as the overlay 8, the decorative layer 7 and the top 31 of the support layer 6 are provided with a structure or surface structure.
  • a nonwoven layer 32 is adhered on the upper side of the carrier layer 6 of the bottom panel 5.
  • the nonwoven layer 32 is printed with a decor forming the decorative layer 7.
  • the side seal forms the overlay 8.
  • a multi-layer body 35 is produced which comprises the carrier layer 6, the decorative layer 7 and an overlay 8. Between the carrier layer 6 and the decorative layer 7, the nonwoven layer 32 can be arranged. The decorative layer 7 may also be printed on the nonwoven layer 32.
  • the overlay 8 is formed by melamine resin, which is applied as a film or powder on the decorative layer 7.
  • the multilayer body 35 is then fed to a press and cured by means of heat and pressure.
  • the pressing operation is carried out at a temperature between 120 ° C and 200 ° C and a pressure between 1,500 kPa and 6,000 kPa.
  • the carrier layer 6 is at least partially elasticized, in particular an elastification takes place in an upper-side layer.
  • the pressing process there is an intimate connection of the layers of the multi-layer body 35, wherein in the pressing process in the bottom panel 1 - 5 surface-side structures and / or degrees of gloss are pressed.
  • mineral materials are mixed with binders of the type provided according to the invention and formed into the carrier layer 6.
  • the large-format plate consisting of support layer 6, decorative layer 7, optionally the nonwoven layer 32 and the overlay 8 is present.
  • This large-format plate is then divided into individual floor panels 1 - 5 and profiled on the longitudinal and top side edges and provided with locking means 11.
  • the floor panel 1 - 5 has a thickness of 4 mm to 12 mm, preferably 5 mm to 6 mm.
  • the single floor panel 1 - 5 is self-laying and needs no bonding to the ground. Sezugs Schweizer:

Landscapes

  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Floor Finish (AREA)

Abstract

L'invention porte sur un revêtement de sol (3) et sur un procédé de fabrication de ce revêtement. Le revêtement de sol (3) présente une couche porteuse (6), une couche de décor (7) et un recouvrement (8) étant disposés au-dessus de la couche porteuse (6). La couche porteuse (6) est composée à base d'une matière minérale et d'un liant. La matière minérale est faite de plâtre et/ou de calcaire et/ou de dolomite, dans une proportion d'au moins 50 % en volume. Le liant est biologiquement dégradable. Les bords latéraux (9, 10) du revêtement de sol (3) sont profilés et munis de moyens de verrouillage (11). La couche de décor (7) peut être imprimée sur la surface de la couche porteuse (6) ou elle peut être imprimée en qualité de décor sur une couche de non tissé (32) qui est déposée sur la couche porteuse (6).
EP12727246.6A 2011-04-05 2012-03-30 Procédé de fabrication d'un revêtement de sol Active EP2694300B1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102011001807.7A DE102011001807B4 (de) 2011-04-05 2011-04-05 Bodenpaneel und Verfahren zu deren Herstellung
PCT/DE2012/000338 WO2012136188A1 (fr) 2011-04-05 2012-03-30 Revêtement de sol et procédé de fabrication de ce revêtement

Publications (2)

Publication Number Publication Date
EP2694300A1 true EP2694300A1 (fr) 2014-02-12
EP2694300B1 EP2694300B1 (fr) 2016-05-18

Family

ID=46275625

Family Applications (1)

Application Number Title Priority Date Filing Date
EP12727246.6A Active EP2694300B1 (fr) 2011-04-05 2012-03-30 Procédé de fabrication d'un revêtement de sol

Country Status (4)

Country Link
EP (1) EP2694300B1 (fr)
DE (1) DE102011001807B4 (fr)
PL (1) PL2694300T3 (fr)
WO (1) WO2012136188A1 (fr)

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EP2829415A1 (fr) * 2013-07-22 2015-01-28 Akzenta Paneele + Profile GmbH Procédé de fabrication d'un panneau mural et de sol décoré
EP3401115B1 (fr) * 2013-07-22 2023-06-07 Akzenta Paneele + Profile GmbH Procédé de fabrication d'un panneau mural ou de sol décoré
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EP2942208A1 (fr) * 2014-05-09 2015-11-11 Akzenta Paneele + Profile GmbH Procédé de fabrication d'un panneau mural ou de sol décoré
RU2711683C2 (ru) * 2015-03-31 2020-01-21 Таркетт Гдл С.А. Элемент минерального синтетического поверхностного покрытия
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Also Published As

Publication number Publication date
WO2012136188A1 (fr) 2012-10-11
DE102011001807B4 (de) 2024-02-08
DE102011001807A1 (de) 2012-10-11
EP2694300B1 (fr) 2016-05-18
PL2694300T3 (pl) 2016-12-30

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