EP2782751A1

EP2782751A1 - Panel, and method for producing a panel

Info

Publication number: EP2782751A1
Application number: EP12808251.8A
Authority: EP
Inventors: Udo Tünte
Original assignee: Huelsta Werke Huels GmbH and Co KG
Current assignee: Huelsta Werke Huels GmbH and Co KG
Priority date: 2011-11-22
Filing date: 2012-11-19
Publication date: 2014-10-01
Also published as: DE202012011048U1; WO2013075813A1

Abstract

A panel (1, 5) is disclosed and described, such as a flooring, wall or ceiling lining panel and/or as a furniture component, housing, covering or drywall panel, and/or as a facade, panel or plank element, screen or the like, having a panel basic body (2) and at least one wear layer (3) which is applied to the panel basic body (2). According to the invention, it is provided that a flat textile structure forms the outer side of the wear layer (3), wherein the flat textile structure has a layer thickness of from 0.2 to 8 mm and the panel basic body (2) has a thickness of from 6 to 10 mm.

Description

Plate and method of making a plate

The invention relates to a plate, such as a floor covering, wall or ceiling trim panel and / or a Möbelbauteil-, housing, covering or Trockenausbauplatte, and / or as a façade, panel or plank element or as a screen, with a plate body and a applied to the plate body preferably upper, outer-side wear layer. Moreover, the present invention relates to a method for producing a plate of the aforementioned type.

Plates of the type mentioned are already known from the prior art and are used in different applications. The known plates usually have a plate base body and an applied on the plate body, outside wear layer. The panel body acts as a support layer and must absorb loads as a supporting or connecting element and ensure lasting dimensional stability. The wear layer is the topmost layer of the board which is either primarily and immediately exposed to human intrusion or contact with other objects and associated mechanical stress, and / or the visual surface is a design function of the panel in the trim or cover or their use as a component takes over. Wear layers can be provided to increase the abrasion or scratch resistance of the plates in question against mechanical stress. In addition, the wear layer may be provided to protect against moisture penetration of the plate body, which is particularly advantageous for the use of the plate outdoors. Decorative layers can give the board base the natural appearance of any raw materials. In addition, wearing layers can contribute to imparting a certain refractoriness and / or a certain substance absorption capacity to the board body.

From WO 2005/066431 A2, a laminate floor panel is already known, which has a support plate and a wear layer with abrasion-resistant particles for protection against wear. In this case, the wear layer has a decorative paper or an elastic decorative foil on which there is a decorative picture.

Object of the present invention is to provide a plate of the type described above with a plate body and an applied to the plate body base wear layer and a method for producing such a plate, wherein the plate by a wear layer with respect to the prior art should feature enhanced functionality.

The above object is achieved in a plate with the preamble features of claim 1, characterized in that a textile fabric forms the outside of the wear layer, wherein the fabric has a layer thickness between 0.2 to 8 mm and the plate body has a thickness between 6 and 10 mm , Previous panels of the type in question have sound-hard surfaces, such as laminates or parquet floors. The invention proposes to form the surface of the plate by using a textile fabric, for example, more sound-absorbing and / or more sound-absorbing than is the case with the known from the prior art plates the case. By the fabric, a soft surface of the plate can be generated, which leads to a pleasant haptic perception when touched by hand. In addition, the textile fabric of the plate can give the appearance of a textile material and thus an aesthetically pleasing appearance. In particular, the textile fabric can also act as a thermal insulation layer. For example, if the panel is a floor covering panel, the fabric may help to make the surface of the panel foot warm. Finally, the textile fabric may have the task of improving a room climate, and / or the textile fabric is permeable, but at the same time preferably waterproof, in order to facilitate drying out of the board body in the event of any moisture contained in the board body. In a diffusion-open configuration of the textile fabric, the lowest possible resistance to steam is realized. At the same time, the watertightness ensures that any liquid present on the textile fabric does not penetrate into the board body. The selected layer thicknesses of the fabric and the plate body is ultimately ensured that on the one hand for the user by the outside provided textile fabric gives the impression of a bottom-side carpet that can be moved very quickly and easily by the proposed plate body on the other hand. It has been found that plate main body with a thickness of greater than 10 mm are usually not required to achieve the purpose of the invention. Layer thicknesses of the textile fabric of greater than 8 mm are usually not required to achieve a sufficient "carpet impression" and the aforementioned advantages when used as a floor covering.

However, the textile fabric preferably meets the requirements for floor coverings according to DIN EN 1307, in particular the requirements for impact sound insulation (DIN EN ISO 140-8), sound absorption (DIN EN 20 354) and / or thermal resistance (ISO 8302). Finally, in the panel according to the invention, the textile fabric can fulfill an impregnation function and / or can be distinguished by a specific fire resistance and thus fulfill a fire protection function. In addition, the use of certain textile materials makes it possible to achieve pollutant-absorbing or reducing effects of the wear layer.

In order to achieve a simple and cost-effective production of the plate according to the invention, the wear layer may be single-layered and formed only by the textile fabric. The sheet essentially determines the dimensions or dimensions of the wear layer. The term "single-layered" within the meaning of the invention, however, allows a textile fabric to be bonded or glued to the board base body using suitable laminating means.

The wear layer may also have a multilayer structure, wherein the textile fabric forms an outer layer with the advantages described above. In addition, at least one intermediate layer is provided between the board base body and the outer layer. Via the intermediate layer, the textile fabric can be fastened to the board base body in a simple and reliable manner. This allows a high abrasion resistance of Textile layer can be achieved. The intermediate layer can also be provided as a further carrier, insulating or insulating layer, in particular as a waterproof insulating layer, and is connected on an inner side with the plate base body, in particular glued, and connected on the outside with the textile sheet material. It can also be several textile layers connected to each other and form the wear layer.

Preferably, a counter-pull is provided on the underside of the plate body in order to avoid distortion of the plate body due to any stresses occurring.

In the context of the invention, a "textile fabric" may be a fiber composite of fibrous materials, wherein the fibrous materials may be selected from the group of vegetable fibers, such as coconut, sisal, jute, cotton or hemp fibers or the like , and / or from the group of animal fibers, such as sheep's wool, goat's hair or silk, and / or from the group of synthetic fibers, such as polyacrylic, polyamide, polyester or polypropylene fibers, or mixtures of the aforementioned groups. It is understood that the aforementioned list of possible pulps is not exhaustive and the skilled person further fiber materials are known, which can basically form a fiber composite.

The fiber composite may also consist of at least two different fibers. In this way, the textile fabric can be given different properties, which are due to the respective types of fiber used, such as in particular sound-absorbing, sound-absorbing, heat-insulating or a certain haptic perception of the fabric ensuring properties. For example, fibers can be incorporated into the textile fabric that absorb or adsorb pollutants in order to create a healthy indoor climate when using the panel indoors.

Preferably, the textile fabric is a woven, knitted or knitted fabric. In principle, the textile layer can also be knotted or tufted. Particularly preferably, the textile layer is formed as a carpet material, namely as a woven or knotted carpet or as carpet material. A carpet can be produced by various processes, such as flocking, Klebepol process, needles, tufts, weaving or knitting, whereby various fiber materials can be used. For example, a velor carpet or a loop carpet can form the textile fabric. Upholstery textiles and upholstery fabrics, which are usually used in furniture construction, are basically suitable and advantageous for use as a textile fabric in the sense of the invention.

In addition, may be provided as a textile fabric, a nonwoven fabric, felt, solid or micro-fiber fabric, such as Alcantara, namely a polyester and polyurethane-based microfibre fabric. From the group of nonwovens may synthetic fiber webs, the chemical fibers of natural or synthetic polymers, such as polyamide (PA), polyethylene (PE), polyvinyl chloride (PVC), polyester, especially polyethylene terephthalate (PET), have, and / or natural fiber webs containing animal fibers such as silk or wool, in particular goat or sheep wool, or vegetable fibers such as hemp or cotton or silk, and / or mineral fiber fleeces having mineral fibers such as glass, asbestos, mineral wool or basalt; be used advantageously. For fiber production, spinning processes, such as dry spinning, wet spinning, melt spinning or matrix spinning, can be used. The solidification may be mechanical, needling or hydroentanglement, or chemical, by the addition of binders, such as water-based acrylate resins or reactive resins, such as phenolic or urea resins, or epoxy or polyurethane binders, or else thermally, by softening in a suitable gas stream , between heated rollers or in a vapor stream, take place. In chemical bonding processes, the binder can be used to improve the mechanical properties of the textile material, such as higher strength and lower tendency to abrasion. Additional impregnations can improve the performance properties. For example, by means of a suitable impregnation, it is possible to reduce the dirt sensitivity of the textile material and to achieve easy cleanability with low care requirements. UV protection is also possible through additional impregnation. As an alternative to conventional formaldehyde-based reactive resins such as phenol or urea-formaldehyde resins or as an alternative to epoxy or polyurethane binders, it is possible to use purely water-based and formaldehyde-free acrylate resins, such as a binder marketed by BASF under the trade name Aerodur® in particular for the production of a nonwoven fabric from natural fibers.

The textile fabric can be applied, in particular laminated, to the board base body in a finished state, which permits a simple and cost-effective production of the board according to the invention. In this embodiment, as a result, a woven, knitted or knitted fabric or a nonwoven fabric, felt, solid or micro fiber fabric is applied to the board body, wherein the textile sheet material is already in a state of use. The textile fabric can be used, for example, as web or roll goods. In particular, in this context, the textile fabric may be a carpet material, wherein the usual in carpets back coating is not required.

In the field of nonwovens so-called "technical textiles" are used, which can be provided in principle as a textile fabric on the plate body. Here, textile materials may be provided which are known from aircraft construction, marine and shipbuilding and the construction industry, such as for use in durable textile roofs. The technical textiles include in particular carbon fiber and polyester composites.

Another aspect of the invention relates to the production of a textile fabric directly on the board body, the fabric "growing up" on the board body. For example, the board body can be sprinkled with textile fibers, which may be covered with a binder in order to produce a textile fabric on the board body. In principle, it is of course also possible for the board base body to be coated with a binder or an adhesive layer in order to achieve bonding of the fibers to the board base body. The sprinkling layer can then be pressed under pressure and heat. During the pressing process, structures can be embossed into the textile layer. The textile fabric can also be formed by flocking the panel body. In this case, an adhesive is first applied to the (primed) surface of the plate body. This can be done by brushing, spraying, knife coating, rolling or dipping. Subsequently, textile fibers are applied as flocking material, which can be done for example with an electrostatic flocking machine. The thickness of the adhesive layer may be at least one fifth of the flock or fiber length, preferably at least one tenth of the flock length. Subsequently, a drying process, for example, an oven drying, join, in which the adhesive layer sets by the heat treatment. The conclusion is the cleaning of the surface of the flocked plate body of excess fibers. For flocking the plate surface preferably polyamide, viscose, polyester and cotton fibers can be used. It is understood that the above enumeration is not exhaustive. By sprinkling or flocking textile fabrics can be produced on the surface of the plate body with a small layer thickness in a simple manner and inexpensively.

The wear layer preferably covers the entire upper surface of the upper flat side of the panel body, more preferably flush. The entire visible in the laying or installed state outer surface of the plate body can then be covered with a textile layer. If necessary, the board base body on both outer flat sides and / or on the transverse and / or longitudinal sides have a textile fabric or a textile layer. A regional coating of the plate body with the textile material is possible. The wear layer may have a layer thickness between 0.2 to 8 mm, preferably between 0.5 to 5 mm, in particular up to 2 mm. The plate main body may have a thickness of 5 to 20 mm, preferably 6 to 10 mm, in particular to 8 mm. It is understood that the required thickness of the plate base body depends on the mechanical load of the plate according to the invention. As already described above, the wear layer can be embossed on the outside, ie have recessed structures, which makes it possible to give the plate the natural appearance of certain raw materials, such as wood or cork.

In order to connect plates according to the invention, the plate main body may have a locking contour, in particular a groove or spring contour for forming a tongue and groove connection or a latching contour for forming a latching connection with an adjacent complementary plate base body. Suitable locking means, for example for the formation of a click connection at the edges of the disk base body, allow the simple connection of individual plates according to the invention with little expenditure of time. An aspect of the invention in this context relates to a plate according to the invention with a plate basic body, which is coated with a carpet material and at its edges locking means, in particular those which are suitable for forming a click connection has. Such panels can be used as floor covering panels and are easier to handle and lay compared to carpets to be laid as rolls or sheets. This aforementioned aspect of the invention may have its own inventive significance.

The board material of the board body can be selected from the group of wood materials, in particular solid wood or plywood, the wood chip materials, wood fiber materials and / or composites on wood, plastic, pulp and / or mineral base, and / or from the group of plastics and / or from the group of minerals and / or from the group of lignin and / or cellulose-based materials and / or from the group of ceramic materials and / or mixtures thereof. In addition, binders and additives may be provided to impart the desired properties to the board material. Most preferably, the panel body is an HDF or MDF panel, which provides the panel with high strength and rigidity and permits cost-effective manufacture. In particular, there are a variety of ways to design and develop the plate according to the invention or the method according to the invention, reference being made on the one hand to the dependent claims and on the other hand to the following description of preferred embodiments of the invention with reference to the drawings. Moreover, the invention makes it possible, if necessary, to combine the features mentioned in the claims and / or the features disclosed and described with reference to the drawing, even if this is not described in detail. The above value specifications and specified intervals in each case capture all values, ie not just the lower limits or, for intervals, the interval limits, without this requiring an explicit mention.

In the drawing show:

1 is a schematic longitudinal sectional view of the layer structure of a first embodiment of a plate according to the invention,

Fig. 2 is a schematic longitudinal sectional view of the layer structure of a second embodiment of a plate according to the invention and

Fig. 3, the plate shown in Fig. 2 in a view from above.

In Fig. 1, the layer structure of a plate 1 is shown schematically, which may be, for example, a floor covering, wall or ceiling panel. In particular, the plate 1 is a panel element.

The plate 1 has a plate main body 2 and an upper wear layer 3 applied to the plate main body 2. The wear layer 3 is present here directly, i. without elastic intermediate layer, applied to the plate body 2. On the underside, there may be a counter-pull 4, which contributes to the dimensional stability of the plate 1.

The wear layer 3 is a textile layer which is produced by sprinkling the base body 2 with textile fibers, which are affixed with a binder, and then compression under pressure and heat has been. Due to the press plate, structures which are not shown in the compression can be impressed into the textile layer. The textile layer can also be formed by flocking, in which case an adhesive is first applied to the primed board base body 2. Subsequently, the flocking with fibers and finally a heat treatment, in which the adhesive layer sets. The thickness of the wear layer 3 is preferably less than 2 mm in the illustrated embodiment.

In Fig. 2, a plate 5 is shown, which also has a plate main body 2 with return 4. In contrast to the embodiment shown in FIG. 1, however, a multi-layer or multi-layered wear layer 3 is provided, which is formed by a textile layer 6 and a backside coating 7. The wear layer 3 may be a carpet material in the embodiment in the form of a loop fabric, which is glued to the top of the base body 2 with the latter. The total thickness of the wear layer 3 may be less than 10 mm, with a thickness of the textile layer 6 of preferably less than 5 mm. The textile layer 6 has loops 8, which create a textile sheet with a base layer 9. The backside coating 7 is usually provided as carpeting for stabilizing the textile layer in carpet materials that are laid as a web or roll, and / or to reduce the risk of slipping for the carpet. However, since in the illustrated panel 5, the panel base body 2 fulfills the actual support function, it is also possible in principle to attach the textile layer 6 directly to the surface of the panel base 2 on the outside thereof, which can also be done by gluing. The backside coating 7 is then not required. The application of a finished carpet material on the plate body 2 is a simple and inexpensive way to equip the plate 5 with a textile layer 6.

Fig. 3 shows the plate 5 shown in Fig. 2 in a view from above. The plate 5 has at the outer edges of springs 10, 11 and corresponding grooves 12, 13, which make it possible to connect a plurality of plates 5 at the longitudinal and transverse edges together to form a floor covering. In particular, the locking means can be used to form a click connection. forms his. The wear layer 3 covers the main body 2 on the visible upper side of the plate 5 over its entire surface. However, the springs 10, 11 are preferably not covered by the wear layer 3, so that a connection between adjacent plates 5 can be easily produced.

It is advantageous if the wear layer 3 is designed at the edges in such a way that the transition between two wear layers 3 in the plate together of adjacent and interconnected plates 5 is not perceived by a viewer. This can be achieved, for example, by a higher fiber density, thickness or length in the region of the edges of the wear layer 3 and / or by fibers of the wear layer 3 projecting beyond the edges of the plate body 2.

The production of the plate 5 shown in Fig. 3 can be done in different ways. On the one hand, it is possible for a large-area plate material to be connected over the entire area to the wear layer 3 first. For example, a textile layer can be laminated. The plate material may have a conventional press dimension of, for example, 2.0 m width and 5.2 m length or of 1.3 m width and 4.8 m length. Prior to cutting out the plates 5 from the plate material, this is made ready for surface, which may include, for example, cleaning the surface of the plate material from excess fibers. After cutting out the plates 5 then the locking contours can be subsequently generated on the plates 5.

In particular, it is to be ensured that the wear layer 3 does not fray on the longitudinal and transverse edges of the plate 5, provided that the locking contours have to be produced after application of the textile layer to the plate base body 2. An alternative way of producing a plate 5 can therefore be to first produce the plate base body 2 with the locking contours and then to provide it with a wear layer. The formation of exact transitions between the wear layer 3 and the edge-side locking contours can thus be ensured in a simple manner. LIST OF REFERENCE NUMBERS

1 plate

2 plate body

3 wear layer

4 return

5 plate

6 textile layer

7 backside coating

8 base course

9 fiber loops

10 spring

1 1 spring

12 groove

Claims

Claims:

1. panel (1, 5), such as floor covering, wall or ceiling trim panel and / or furniture component, housing, cover or drywall, and / or as facade, panel or floorboard element, screen or the like, with a plate body (2) and at least one wear layer (3) applied to the board base body (2), characterized in that a textile fabric forms the outside of the wear layer (3), wherein the textile fabric has a layer thickness between 0.2 to 8 mm and the board base body (2) has a thickness of 6 to 10 mm.

2. Plate according to claim 1, characterized in that the wear layer (3) is multi-layered, wherein the textile fabric forms an outer layer.

3. Plate according to claim 1 or 2, characterized in that at least one intermediate layer between the plate base body (2) and the textile fabric is provided as the outer layer.

4. Plate according to claim 3, characterized in that the intermediate layer is formed as an insulating layer.

5. Plate according to one of the preceding claims, characterized in that on the underside of the plate base body (2) a counter-pull (4) is provided.

6. Plate according to one of the preceding claims, characterized in that the textile fabric comprises a fiber composite of fibrous materials, wherein the fibrous materials are selected from the group of vegetable fibers, such as coconut, sisal, jute, cotton or hemp fibers, and / or the group of animal fibers, such as sheep's wool, goat's hair or silk, and / or the group of synthetic fibers, such as polyacrylic, polyamide, polyester or polypropylene fibers, or mixtures of the aforementioned groups and / or that the textile fabric comprises a fiber composite has at least two different fibers.

7. Plate according to one of the preceding claims, characterized in that the textile fabric is a woven, knitted fabric or knitted fabric or a nonwoven fabric, felt, Wound fabric or micro fiber fabric and / or that the textile fabric is a carpet material.

8. Plate according to one of the preceding claims, characterized in that the textile fabric is applied as a carpet material without back coating of a finished carpet material on the plate body, in particular glued.

9. Plate according to one of the preceding claims, characterized in that the textile fabric is produced on the plate base body (2), in particular by flocking or sprinkling of the plate base body (2) with a fiber material.

10. Plate according to one of the preceding claims, characterized in that the wear layer (3) the plate body (2) over the entire surface and, preferably, flush, covers.

11. Plate according to one of the preceding claims, characterized in that the wear layer (3) has a layer thickness between 0.2 to 8 mm, preferably between 0.5 to 5 mm, in particular to 2 mm and / or that the textile fabric has a layer thickness between 0.5 to 5mm, in particular up to 2 mm.

12. A method for producing a plate (1, 5), such as floor covering, wall or ceiling panel and / or furniture component, housing, Abdeckoder drywall, and / or as a facade, panel or floorboard or screen, in particular a plate (1 5) according to one of the preceding claims, with a panel base body (2), wherein a textile fabric is applied to at least one outer surface of the panel base body (2).

13. A method for producing a panel (1, 5), such as floor covering, wall or ceiling trim panel and / or furniture component, housing, Abdeckoder drywall panel, and / or as facade, panel or Dielenele- ment or screen, in particular a plate (1, 5) according to any one of the preceding claims, wherein a large-area plate material is fully bonded to the fabric, wherein the large plate material is cut together with the fabric into plates (1, 5) and wherein then the locking contours on the plates (1, 5) are produced.

14. The method according to claim 12 or 13, characterized in that the textile fabric is applied by lamination to the plate body (2) or the large-area plate material or that the textile fabric is produced on the plate body (2) or the large-area plate material.