EP2799642A1

EP2799642A1 - Wainscot panel and its production method

Info

Publication number: EP2799642A1
Application number: EP20140460023
Authority: EP
Inventors: Pawel Wegrzyn; Jerzy Gil; Pawel Gwizdalski
Original assignee: Fachuro Remontowo-Budowlana GWIZDALSKI Pawel Firma; Produkcyjno-Handlowa SEPPA sc GIL Jerzy WEGRZYN Pawel Firma
Current assignee: Fachuro Remontowo-Budowlana GWIZDALSKI Pawel Firma; Produkcyjno-Handlowa SEPPA sc GIL Jerzy WEGRZYN Pawel Firma
Priority date: 2013-05-02
Filing date: 2014-04-29
Publication date: 2014-11-05
Also published as: PL403742A1

Abstract

The object of the patent is the method of manufacturing wainscot panels and the wainscot panel (1) produced using this method. The patent is applied in production of wainscot panels (1) for external use for building facades as well as for internal use for wall or ceiling facings.

The wainscot panel (1) imitates natural structure. It has a support layer (2) and a facade finish layer (3), where the facade finish layer (3) is at least made of one facade finish coating (4), and between the support layer (2) and the facade finish layer (3) there is at least one intermediate layer (5,5'). The last surface layer in relation to the support layer (2) is the protective coating (6), and the facade finish coating (4) is printing paint. The wainscot panel (1) has at least two through holes (7) of axially changing diameters (D', D"), where each one has the wider diameter (D') on the facade finish side (3) and the narrower diameter (D") on the bottom side (8) of the support layer (2). In the through holes (7) there are anchors (9), whose wider end is on the decorative surface side (3') and is hidden in the through hole (7) inside the support layer (2). At least a part of the anchor (9) rests on the edge of the hole (13) of the larger diameter (D'). The anchor (9) is masked with at least one priming layer (5,5') and at least one layer of the decorative surface (3') and preferably with the protective coating (6). The geometric structure of the decorative surface (3') and the internal structure of the support layer (2 through its density and/or hardness is approximately adequate to the geometric surface structure and density and/or hardness respectively of the natural structure that it imitates.

Description

The object of the patent is the method of manufacturing wainscot panels and the wainscot panel produced using this method. The patent is applied in production of wainscot panels for external use for building facades as well as for internal use for wall or ceiling facings.
It is common knowledge that wainscot panels are usually produced from wood in order to attain aesthetic effect through natural surface structure of such panels. Individual panels are cut to the desired size, they are polished and covered with a protective layer, preferably lacquer, having been impregnated earlier. The known methods of mounting panels by nailing or screwing them result in losing the aesthetic value, because the mounting points are visible, and the surface structure is damaged. Therefore, other solutions have been developed to replace this commonly used panel. Those solutions were adopted depending on their destination or aesthetics through another, internal or external, panel structure, or even through the mounting system.
For example, there is a wainscot element known from patent application no. PL318425 , which is used for external and internal walls facade finish. The element consists of permanently joined support layer, preferably made of plastic, and the face layer, preferably made of foil of any surface texture and colour. In this solution it was attempted to point to a banal modification providing an imitation of the surface structure and the change in panel properties. Furthermore, the imitation is far from the original, and the internal physical properties of the panel are not appropriate for this imitation, because it is not expected for foil to imitate plastic that is easy to identify.
There are panels for external use as building facade finish and as internal panels for walls known from patent application no. PL393840 . The first layer of each panel is a wood-based plate of the OSB type. The plate is the base for the panel core, which is expanded polystyrene in the shape of a half-balk. Other layers are cork and wood veneer. The purpose of applied additional layers is to protect the panel core from unfavourable weather conditions as well as they have aesthetic function of imitating wood. Panel elements are pressed together using one-component polyurethane-based glue. Hardening is achieved through the humidity contained in the air. The glue is resistant to weather conditions. The external visible part of the panel is impregnated and lacquered. In the presented solution the summary panel weight is still considerable. The mounting system is either very complicated or unreliable and not durable. The panel seems to be not prepared for changeable weather conditions, and the imitation is limited to simulating wood.
Therefore, the face finish panel is known from patent application no. PL390944 which imitates rock, especially sandstone. It has a support layer and a facade finish layer. The support layer is made of expanded polystyrene or extruded polystyrene, and the face finish layer is made of at least one synthetic resin-based layer or a combination of synthetic resins containing aggregate composite, especially quartz, coloured with natural pigment. Between them there is a layer made of glass fibre and dispersion glue with mineral filling material. Whereas, the method of producing such a facade finish panel consists in the facade finish layer being applied directly or indirectly on the support layer using painting methods, especially the spraying method. Imitation of this solution is limited to rock materials, especially with rough surfaces. Imitation is also brittle and in the organoleptic contact does not convey the imitated material.
Another technology of imitating granite or marble is known from the patent application no. PL388806 . According to it, a digital picture is printed on the decorative surface of the medium and it is protected by resin, but it is printed with the known technique on the absorptive medium, preferably on silicone paper or silicone or Teflon foil using non-dissolvent printing paints fixed by radical or cationic polymerisation, under a stream of electrons or UV light, after which, before hardening of the last layer using forms filled with resins the printed picture is applied from the non-absorptive medium and is fixed in this resin. Everything is filled in with the construction layer made of a mixture of synthetic resin with natural or synthetic filling material. The described technology is the best possible for imitating the original, however it does not present any possibility to use it for wainscot panels especially not recommended to adopt to the optimal joining method.
None of the mentioned solutions or production technologies, or even none of the known ones indicate optimization related to possibly most genuine imitation of the copied material, both for the imitation of wood and the imitation of granite or marble, or any other stone or architectural concrete by manufacturing this imitation using identical methods, at the same time, rendering the internal structure of the imitated material as accurately as possible. None of the previously known methods make it possible to produce a panel with such properties and with such care for coupling and mounting system optimal for this imitation, which is capable of providing the best possible hold of the wainscot panel both at heights of vertical surfaces, and even on ceilings in accordance with all the construction and fire prevention standards. These standards do not allow for the possibility to mount elements using dispersion adhesives or other unreliable, undurable connectors.
The objective of this solution, according to the patent, is creating a wainscot panel during a single technological process using a method which perfectly imitates a different kind of material with its structure and at the same time during this process it implements a connection system, which does not damage the surface of the wainscot panel, and the panel itself is ready for express mounting immediately after being manufactured without damaging any part of its structure or shape and together with adjacent panels it is capable of covering large surfaces leaving the prefabricated connection system invisible.
The method of manufacturing the wainscot panel which imitates natural structures, according to the invention is achieved through printing the decorative surface onto the support layer and preferably securing it. This surface is printed with a known technique using printing paint fixed by radical or cationic polymerisation or by treating it with a stream of electrons or by treating it with UV light. The support structure is adjusted to the desired size. According to the invention this method is characterised by cutting out and smoothing the support layer surface before applying the printing process at least on the printed side, where the process of cutting out consists of making at least two through holes with axially changing diameters in a certain distance from each other and from the side edge of the support layer. Anchors are inserted into the through holes pointing the narrow end forward so that the wider end of the anchor, on the decorative side, is hidden inside the through hole and rests on the edge of the hole. Such an inserted anchor is masked with a layer of a decorative surface, which is applied onto the previously applied, preferably degreased, priming layer. The geometric structure of the decorative layer and the internal structure of the support layer through its density and/or hardness is selected so that it is approximately adequate to the geometric surface structure and density and/or hardness respectively of the natural structure that it imitates. The priming layer is preferably the surfacer, which is smoothed on the printed side. Independently, as the priming layer, preferably paint is applied and/or grounding primer. The surface of the support layer can be smoothed by grinding before applying the priming layer and/or after applying the priming layer. The printed surface can be protected with lacquer, and lacquering can be done using an automatic sprinkler. Next the lacquer can be seasoned until it hardens or soaked until it hardens preferably in a soaking chamber. The support layer can be adjusted to the required size by cutting and/or machining, and it can be performed best in a digital machining centre. It is especially important for the case where cutting of the support layer to the desired size includes preparing elements of an alternative coupling of the feather type. If such a coupling type is implemented, the through holes can be drilled in the feather of this coupling, however it is also possible regardless if the feather has such through holes for anchors, it is preferable to drill those through holes away from the feather coupling. Anchors can be screwed in into the through holes and/or glued in and/or pushed in. The printing process can be performed in standard and/or digital printing machines, depending on the printed layer or the surface for which the most favourable method is best suited in terms of durability, production possibilities, adherence, etc. Regardless of the selected printing method, the process of adjusting size to the desired dimensions, the process of cutting, especially the drilling process, the process of inserting anchors into the holes, the process of applying the priming layer, the smoothing process and the printing process are preferably performed in one production process and in one machine line, which allows to reduce the time of manufacturing elements, to make sure that the highest care and accuracy is maintained to minimise waste, to minimize faulty elements.
According to the patent, the wainscot panel is an imitation of natural structure. It has a support layer and a facade finish layer, where the decorative surface as the facade finish layer is at least one facade finish coating, and between the support layer and the facade finish layer there is at least one intermediate layer, and the last surface layer in relation to the support layer preferably is a protective coating, and the facade finish layer is printing paint. The support layer is a two-sided flat facing plate of a specific size and shape. The wainscot panel is characterised by having at least two through holes with axially changing diameters, and each of them has the wider diameter on the facade finish layer and the narrower diameter on the bottom side of the support layer. Inside the through holes there are anchors, whose wider ends are on the decorative side and they are hidden in the through hole inside the support layer, and at least a part of the anchor is resting on the edge of the wider diameter of the hole, whereas the anchor is masked with at least one priming layer and at least one layer of the decorative surface and preferably with a protective coating. The geometric structure of the decorative surface and the internal structure of the support layer through its density and/or hardness is approximately adequate to the geometric surface structure and density and/or hardness respectively of the natural structure that it imitates. The protective coating is preferably a lacquer layer, the best would be thermally hardened lacquer. The priming layer is preferably the surfacer. Independently, as the priming layer, paint and/or grounding primer can be applied. The support layer can include alternative coupling of the feather type. The through holes can be drilled in the feather of this coupling or away from the feather coupling, if such coupling exists. Anchors preferably have an outside thread or are smooth from the outside. Anchors can be closely fitted to the support layer and/or they can be fixed in the support layer using an adhesive layer. The geometric structure of the decorative surface preferably resembles the surface structure of wood or cork and at the same time the support layer is particle board or MDF board or HDF board or plywood. The geometric structure of the decorative surface preferably resembles the surface structure of granite or marble or sandstone and at the same time the support layer is cement-bonded particleboard or cement-limestone board or cement-mineral. Anchors preferably have, at least on the bottom side of the support layer, an axial hole that is internal for the anchor, whose walls are threaded. The through holes together with anchors fixed inside them preferably are located in the corner areas of the facing plate and/or near the edges of the facing plate. The size of the facing plate flat on both sides is preferably such that its length is an integer multiple of its width.
The lengths of two different facing plates preferably are an integer multiple in relation to each other. When calculating the above mentioned length proportions and/or the width of the facing plate is reduced by the height of the feather of the feather coupling. A single facing plate can have externally measured surface of 0.2 m2 to 10 m2
An additional advantage of this solution according to the patent, is good acoustic insulation of the panel, and as a consequence good acoustic insulation of the whole surface covered with the panels, fire protection parameters are similarly advantageous. Another advantage is also the possibility to construct elevation perceived as stone, without the necessity of using three-layer walls of the building.
Another unquestioned advantage is however superior accuracy of imitation in comparison with currently known imitating products, achieved most of all by high resolution of the geometrical structure of 600DPI and more, and also by the structure and construction of the support layer of the imitation according to the patent. The patent also allows to take advantage of its characteristics, especially the one which concerns the weight of an element, which can be about a dozen times lower than the natural material which it imitates. Reliability and strength of the connectors makes it possible to mount those accurate imitations at heights including mounting on the ceiling, which is difficult or impossible for other solutions, especially when it is necessary to meet the demanding building and fire protection norms.
The patent solution is presented in an example construction on a drawing where :

Fig.1 presents the support layer seen from above with drilled through holes after cutting and before embedding the anchors; Fig.2 presents a construction element of the support layer during embedding of the anchors in it, Fig.3 presents a finished wainscot panel with concrete imitation from perspective, Fig. 4 presents a wainscot panel in a different version with alternative connection in a section, and Fig.5 presents a construction element of a different version as two adjacent wainscot panels fixed on a surface with an anchor in a section viewed from the side.

Example 1

An example method of producing a wainscot panel 1, which is an imitation of natural structure, consists in printing with a decorative surface 3' on the support layer 2 and protecting it. The surface 3' is printed with a known technique using printing paints fixed using UV light. The support layer 2 is adjusted to the desired size of 2.5m in length and 0.5m in width and 3cm in thickness. Before the printing process, the support layer 2 is cut and all of its surfaces are smoothed. The cutting process consists in drilling eighteen through holes 7 of axially changing diameters D', D" 25cm apart from each other and 12.5cm from the side edge 16 of the support layer 2. Each through hole 7 has two diameters D', D". Anchors 9 are inserted into the through holes 7 with the narrower end forward so that the wider end of the anchor 9 being on the decorative side of the surface 3' is hidden inside the through hole 7 and rests on the internal edge of the hole 13 and on the bottom edge of the wider diameter D'. Such a fixed anchor 9 is masked with a layer of the decorative surface 3', which is applied onto the previously applied, degreased priming layer 5, 5'. The geometric structure of the decorative surface 3' and the internal structure of the support layer 2 through its hardness is approximately adequate to the geometric surface structure and the hardness of the natural structure of concrete, which it imitates. Surfacer is applied as the priming layer 5', which is smoothed on the printed side. Independently, as the priming layer 5 paint is applied as the grounding primer. The surface of the support layer 2 is smoothed by grinding after the priming layer has been applied 5, 5'. The printed surface is protected by lacquering, and the lacquering is performed using an automatic sprinkler, and the lacquer is heated in a soaking chamber until it hardens. The support layer 2 is prepared by cutting and machining in a digital machining centre. Anchors 9 are glued in and pushed in at the same time into the through holes 7. The printing process is performed in digital printing machines. The process of adjusting size to the desired dimensions, the process of drilling, the process of inserting anchors 9 into the holes 13, the process of applying the priming layer 5, 5', the process of smoothing and the process of printing are performed in one production process and in one machine line.
The wainscot panel 1 is an imitation of natural structure having the support layer 2 and the face finish layer 3, where the decorative surface 3' as the face finish layer 3 is a triple face finish coating 4, and between the support layer 2 and the face finish layer 3 there are two intermediate layers 5, 5', where the last surface layer 6 in relation to the support layer 2 is protective coating 6'. The face finish coating 4 is printing paint. The support layer 2 is made of facing plate 1' of specific size and shape flat on both sides. The wainscot panel 1 has eighteen through holes 7 of axially changing diameters D', D", whose wider diameter D' is on the side of the face finish layer 3 and the narrow diameter D" is on the bottom side 8 of the support layer 2. Anchors 9 are inserted into the through holes 7, whose wider end 10' is on the side of the decorative surface 3' and is hidden inside the through hole 7 inside the support layer 2. The anchor 9 is a pin 9' with a flat disc on one side 10, and the pin 9' is hollow inside and is threaded on the inside 11. The bottom 12 of the disc 10 of the anchor 9 rests on the bottom of the hole edge 13 of the wider diameter D', whereas the anchor 9 is masked with surfacer 5' as the priming layer and with grounding primer paint 5 and a triple layer of the face finish coating 4 and the protective coating 6'. The geometric structure of the decorative surface 3' and the internal structure of the support layer 2 through its hardness is approximately adequate to the geometric surface structure and respectively the hardness of the natural structure of concrete, which it imitates. The protective coating 6' is a layer of thermally hardened lacquer. Anchors 9 are smooth on the outside. Anchors 9 are closely adjacent to the support layer 2 and at the same time they are embedded in the support layer 2 through using the adhesive layer 14. The support layer 2 is particle board. Through holes 7 together with anchors 9 embedded in them are on the entire surface of the support layer 2, also in the corner areas 15 of the face plate 1' and also in the area of the side edges 16 of the face plate 1'. The dimensions of the face plate 1' flat on both sides are such that its length is five time integer multiple of its width. A single face plate 1' has surface measured on one side of 1.25 m2.

Example 2

The same as in the first example, but the support layer 2 includes alternative coupling 17 of the feather type. Through holes 7 are drilled in the feather 18 of the coupling 17 of the feather type.
The geometric structure of the decorative surface 3' is the same as surface structure of marble and the support layer 2 is a cement-bonded particleboard. There are eleven through holes 7, separated every 25cm near two edges 16 separated every 25 cm from each other. The face plate 1' has the same dimensions, but when the length and width of the face plate 1' are given they are reduced by the feather 18 of the coupling 17 of the feather type.

Claims

The method of manufacturing wainscot panels that are imitating natural structure by printing a decorative surface on the support layer and preferably protecting it, but this surface is printed with a known technique using printing paints fixed by radical or cationic polymerisation or under a stream of electrons or UV light, and the support surface is adjusted to the desired dimensions, characterised by cutting and smoothing the surface of the support layer (2) at least from the printed side before the printing process starts, where the process of cutting at least consists in drilling, in a certain distance from one another and from the side edge (16), in the support layer at least two through holes (7) with axially changing diameters (D', D"), and into the through holes (7) anchors (9) are inserted with the narrower end forward so that the wider end of the anchor (9) being on the decorative surface side (3') is hidden in the through hole (7) and it rests on the edge of the hole (13), and such anchor (9) is masked with a layer of the decorative surface (3'), which is applied on the previously applied, preferably degreased, priming layer (5,5'), where the geometric structure of the decorative layer (3') and the internal structure of the support layer (2) through its density and/or hardness is selected so that it is approximately adequate to the geometric surface structure and density and/or hardness respectively of the natural structure that it imitates
The method of manufacturing the wainscot panel in accordance with claim 1, characterised in that the priming layer (5') surfacer is used, which is smoothed on the printed side
The method of manufacturing the wainscot panel in accordance with claim 1, characterised in that the priming layer (5) paint and/or grounding primer is applied
The method of manufacturing the wainscot panel in accordance with claim 1 or claim 2 or claim 3, characterised in that the surface of the support layer is smoothed (2) by grinding before applying the priming layer (5,5') and/or after applying the priming layer (5,5')
The method of manufacturing the wainscot panel in accordance with claim 1 or claim 2 or claim 3 or claim 4, characterised in that the printed surface is protected by lacquering
The method of manufacturing the wainscot panel in accordance with claim 5, characterised in that it is lacquered using an automatic sprinkler, and next the lacquer is seasoned until it hardens or soak until it hardens preferably in a soaking chamber
The method of manufacturing the wainscot panel in accordance with any claim from 1 to 6, characterised in that the support layer (2) is adjusted to the required size by cutting and/or machining, preferably in a digital machining centre
The method of manufacturing the wainscot panel in accordance with claim 7, characterised in that adjusting the support layer (2) to the desired dimensions includes making elements of alternative coupling (18) of the feather type
The method of manufacturing the wainscot panel in accordance with claim 9, characterised in that through holes (7) are drilled in the feather (17) of the coupling (18) of the feather type
The method of manufacturing the wainscot panel in accordance with claim 9, characterised in that through holes (7) are drilled away from the coupling (18) of the feather type
The method of manufacturing the wainscot panel in accordance with any claim from 1 to 10, characterised in that anchors (9) are screwed in and/or glued in and/or pushed in
The method of manufacturing the wainscot panel in accordance with any claim from 1 to 13, characterised in that the pro1cess of printing is carried out in standard and/or digital printing machines
The method of manufacturing the wainscot panel in accordance with any claim from 1 to 14, characterised in that the process of adjusting the size to the desired dimensions, the process of cutting, especially drilling, the process of inserting anchors (9) into holes (13), the process of applying the priming layer, the smoothing process and the printing process are preferably performed in one production process and in one machine line
A wainscot panel imitating natural structure having the support layer and the face finish layer, where the decorative layer as the facade finish layer is at least one elevation coating, and between them there is at least one intermediate layer, and the last surface layer in relation to the support layer preferably is a protective coating, and the facade finish layer is printing paint, where the support layer is a two-sided flat facing plate of a specific size and shape, characterised in that it has at least two through holes (7) axially changing diameters (D', D"), and each of them has the wider diameter (D') on the side of the facade finish layer (3) and the narrower diameter (D") on the bottom side (8) of the support layer (2) and in the through holes (7) there are anchors (9), whose wider ends are on the decorative side (3') and is hidden in the through hole (7) inside the support layer (2) and at least a part of the anchor (9) is resting on the edge of the hole (13) of the wider diameter (D'), whereas the anchor (9) is masked with at least one priming layer (5, 5') and at least one layer of the decorative surface (3') and preferably with a protective coating (6), where the geometric structure of the decorative surface (3') and the internal structure of the support layer (2) through its density and/or hardness is approximately adequate to the geometric surface structure and density and/or hardness respectively of the natural structure that it imitates
Wainscot panel in accordance with claim 14, characterised in that the protective coating (6) is a lacquer layer, preferably thermally hardened
Wainscot panel in accordance with claim 14 or claim 15, characterised in that the priming layer (5') is the surfacer
Wainscot panel in accordance with claim 14 or claim 15 or claim 16, characterised in that the priming layer (5) is paint and/or grounding primer
Wainscot panel in accordance with any claim from 14 to 17, characterised in that the support layer (2) includes alternative coupling (18) of the feather type
Wainscot panel in accordance with claim 18, characterised in that through holes (7) are drilled in the feather (17) of the coupling (18) of the feather type or away from the coupling (18) of the feather type
Wainscot panel in accordance with any claim from 14 to 19, characterised in that anchors (9) have an outside thread or are smooth from the outside
Wainscot panel in accordance with claim 20, characterised in that anchors (9) closely fitted to the support layer (2) and/or they are fixed in the support layer (2) using an adhesive layer (14)
Wainscot panel in accordance with any claim from 14 to 21, characterised in that the geometric structure of the decorative surface (3') is the same as the surface structure of wood or cork and at the same time the support layer (2) is particle board or MDF board or HDF board or plywood
Wainscot panel in accordance with any claim from 14 to 21, characterised in that the geometric structure of the decorative surface (3') is the same as the surface structure of granite or marble or sandstone and at the same time the support layer (2) is cement-bonded particleboard or cement-limestone board or cement-mineral
Wainscot panel in accordance with any claim from 14 to 23, characterised in that anchors (9) have, at least on the bottom side (8) of the support layer (2), an axial hole (11) that is internal for the anchor (9) , whose walls are threaded
Wainscot panel in accordance with any claim from 14 to 23, characterised in that the through holes (7) together with anchors (9) fixed inside them are located in the corner areas (15) of the facing plate (1') and/or near the edges (16) of the facing plate (1')
Wainscot panel in accordance with any claim from 14 to 25, characterised in that the size of the facing plate (1') flat on both sides is such that its length is an integer multiple of its width
Wainscot panel in accordance with any claim from 14 to 26, characterised in that the lengths of two different facing plates (1') are an integer multiple in relation to each other
Wainscot panel in accordance with claim 26 or claim 27, characterised in that the length and/or width of the facing plate (1') is reduced by the height of the feather (17) of the coupling (18) of the feather type
Wainscot panel in accordance with any claim from 14 to 28, characterised in that a single facing plate (1') has a one-side surface of 0.2 m2 to 10 m2.