EP2829415A1 - Procédé de fabrication d'un panneau mural et de sol décoré - Google Patents

Procédé de fabrication d'un panneau mural et de sol décoré Download PDF

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Publication number
EP2829415A1
EP2829415A1 EP13177453.1A EP13177453A EP2829415A1 EP 2829415 A1 EP2829415 A1 EP 2829415A1 EP 13177453 A EP13177453 A EP 13177453A EP 2829415 A1 EP2829415 A1 EP 2829415A1
Authority
EP
European Patent Office
Prior art keywords
carrier
panel
floor panel
wood
decorative
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.)
Withdrawn
Application number
EP13177453.1A
Other languages
German (de)
English (en)
Inventor
Hans-Jürgen HANNIG
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.)
Akzenta Paneele and Profile GmbH
Original Assignee
Akzenta Paneele and Profile GmbH
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 Akzenta Paneele and Profile GmbH filed Critical Akzenta Paneele and Profile GmbH
Priority to EP13177453.1A priority Critical patent/EP2829415A1/fr
Priority to PCT/EP2014/065509 priority patent/WO2015011049A1/fr
Priority to JP2016528463A priority patent/JP6333375B2/ja
Priority to ES14739847.3T priority patent/ES2687372T3/es
Priority to PT14739847T priority patent/PT3024669T/pt
Priority to UAA201601637A priority patent/UA115101C2/uk
Priority to EP18172580.5A priority patent/EP3401115B1/fr
Priority to AU2014295241A priority patent/AU2014295241A1/en
Priority to BR112016000124-9A priority patent/BR112016000124B1/pt
Priority to MYPI2015704445A priority patent/MY177467A/en
Priority to KR1020167002249A priority patent/KR102095082B1/ko
Priority to US14/419,798 priority patent/US10059072B2/en
Priority to MX2015017824A priority patent/MX366767B/es
Priority to EP14739847.3A priority patent/EP3024669B1/fr
Priority to KR1020187006238A priority patent/KR20180028543A/ko
Priority to CN201480035168.4A priority patent/CN105307869B/zh
Priority to RU2016105441A priority patent/RU2635043C2/ru
Priority to TR2018/12933T priority patent/TR201812933T4/tr
Priority to CA2912978A priority patent/CA2912978C/fr
Priority to PL14739847T priority patent/PL3024669T3/pl
Publication of EP2829415A1 publication Critical patent/EP2829415A1/fr
Priority to CL2015003750A priority patent/CL2015003750A1/es
Withdrawn legal-status Critical Current

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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

Definitions

  • the present invention relates to a method for producing a decorated wall or floor panel, to an apparatus for producing a decorated wall or floor panel, and to a wall or floor panel produced according to such a method.
  • Decorated panels are known per se, whereby the term wall panel is also to be understood as panels which are suitable for ceiling clothing. They usually consist of a carrier or core made of a solid material, for example a wood material, which is provided on at least one side with a decorative layer and a cover layer and optionally with other layers, for example, arranged between the decorative and cover layer wear layer.
  • the decorative layer is usually a printed paper impregnated with a resin.
  • the top layer and the remaining layers are usually made of resin.
  • the production of the panels such as the core or the carrier may possibly still offer room for improvement.
  • decorated wall or floor panel or “decorative panel” is to be understood in the context of the invention, in particular wall, ceiling or floor panels, which have a applied to a support plate a decorative template replica decor.
  • Decorative panels are used in a variety of ways, both in the field of interior design of rooms, as well as decorative cladding of buildings, for example in exhibition construction.
  • One of the most common uses of decorative panels is their use as floor coverings.
  • the decorative panels often have a decor that is intended to recreate a natural material.
  • Examples of such modeled natural materials or decorative patterns are wood species such as maple, oak, birch, cherry, ash, walnut, chestnut, wenge or exotic woods such as panga panga, mahogany, bamboo and bubinga.
  • wood species such as maple, oak, birch, cherry, ash, walnut, chestnut, wenge or exotic woods such as panga panga, mahogany, bamboo and bubinga.
  • many natural materials are modeled on stone surfaces or ceramic surfaces.
  • a "decor template” in the sense of the present invention may be understood as meaning, in particular, such an original natural material or at least a surface of one which is to be imitated or imitated by the decor.
  • a "pourable” material may, in particular, be understood as meaning a material which can be applied to a substrate by a pouring process or spreading process.
  • the material may be present as a fluid or in particular as a pourable solid.
  • a "granulate” or a “granular material” can be understood as meaning a solid or a heap of a solid which comprises or consists of a multiplicity of solid particles, such as grains or spheres.
  • granular or pulverulent materials may be mentioned here.
  • a "support” may in particular be understood as a layer serving as a core or as a base layer in a finished panel, which may in particular comprise a natural material, such as a wood-based material, a fiber material or a material comprising a plastic.
  • a natural material such as a wood-based material, a fiber material or a material comprising a plastic.
  • the wearer may already impart or contribute to the panel a suitable stability.
  • a “web-like carrier” may be understood to mean a carrier which, in its production process, has a web-like and therefore significantly greater length compared to its thickness or width and whose length may be, for example, greater than 15 meters.
  • a "plate-shaped carrier” can also be understood to mean a carrier which is formed by singulation from the web-like carrier and is designed in the form of a plate. Furthermore, the plate-shaped carrier already pretend the shape and / or size of the panel to be produced. However, the plate-shaped carrier may also be provided as a large plate.
  • a large plate according to the invention is in particular a carrier whose dimensions exceed the dimensions of the final decorative panels by a multiple and which is divided in the course of the manufacturing process into a corresponding plurality of decorative panels, for example by sawing, laser or water jet cutting.
  • the large plate can correspond to the web-shaped carrier.
  • Wood materials in the context of the invention are in addition to solid wood materials such as cross-laminated timber, glued laminated timber, hardwood plywood, plywood, laminated veneer lumber, Funierstsammlungholz and bending plywood.
  • wood chip materials such as chipboard, extruded plates, coarse chipboard (Oriented Structural Board, OSB) and chipboard wood as well as wood fiber materials such as wood fiber insulation boards (HFD), medium-hard and hard fiberboard (MB, HFH), and especially medium-density fiberboard (MDF) and high-density fiberboard (HDF) to understand.
  • wood materials such as wood-polymer materials (WPC), sandwich panels of a lightweight core material such as foam, rigid foam or paper honeycomb and a wood layer applied thereto, as well as mineral, such as cement, bonded wood chipboard form wood materials in the context of the invention.
  • WPC wood-polymer materials
  • sandwich panels of a lightweight core material such as foam, rigid foam or paper honeycomb and a wood layer applied thereto, as well as mineral, such as cement, bonded wood chipboard form wood materials in the context of the invention.
  • Cork also represents a wood material in the context of the invention.
  • fiber materials means materials such as paper and nonwovens based on vegetable, animal, mineral or even artificial fibers, as well as cardboard.
  • fiber materials made of vegetable fibers and in addition to papers and webs of cellulose fibers plates of biomass such as straw, corn straw, bamboo, foliage, algae extracts, hemp, cotton or oil palm fibers.
  • animal fiber materials include keratin-based materials such as wool or horsehair.
  • mineral fiber materials are mineral wool or glass wool.
  • the method for producing a wall or floor panel comprises the following method steps.
  • a carrier or a core is generated.
  • the above-described method comprises according to method step a) first of all providing a pourable carrier material.
  • the carrier material serves as the basis for the production of in particular plate-shaped carriers for panels. It may be present, for example, as a uniform material or as a material mixture of two or more materials.
  • the support material or at least one constituent of the support material should have a melting point or a softening point in order to form the support material in a further process step by the action of heat, as explained in detail below.
  • the support material can be provided as a pourable solid or as granules, wherein the granules can have a grain size in a range of ⁇ 100 microns to ⁇ 10 mm purely by way of example, depending on the material used.
  • This allows a problem-free storage life and also a particularly good adaptability to a desired material composition.
  • a particularly homogeneous mixture of various components can be produced, with a particularly defined mixture is obtainable with a precisely adjustable composition.
  • so-called dry blends can be used, ie dry plastic powders with additives.
  • the pourable, in particular granular, carrier material is arranged between two belt-like conveying means.
  • a lower belt-like conveyor is circulating and at a defined distance from the lower conveyor an upper belt-like conveyor is moved circumferentially.
  • the carrier material can be applied to the lower conveyor and then limited by the lower and the upper conveyor.
  • the carrier material can thus be conveyed to or through individual processing stations and processed into a carrier. Furthermore, the carrier material can already be preformed in this process step.
  • the belt-like conveying means can take on two functions, namely that of a means of transport and that of a mold.
  • the band-like conveying means may be at least partially made of Teflon or polytetrafluoroethylene (PTFE).
  • the bands may be formed entirely of polytetrafluoroethylene, or bands provided with an outer coating of polytetrafluoroethylene may be used. In the latter case, glass fiber reinforced plastic tapes can be used.
  • polyterafluoroethylene is resistant to chemicals as well as against decomposition even at high temperatures, so that on the one hand a problem-free temperature treatment of the carrier material is possible and the funding is also stable for a long period of time.
  • the carrier material can be freely selectable.
  • the discharging of the carrier material according to method step b) can be realized in particular by means of one or a plurality of scattering heads, which can discharge the carrier material in a defined manner.
  • the scattering heads these may for example be part of a scattering unit and have at least one rotating scattering roller.
  • a funnel can be provided, which can carry out the material to be discharged defined on the scattering roller.
  • a doctor may further be provided which sweeps the material in recesses of the roller.
  • the material can be discharged by means of a rotating brush roller from the scattering roller, where it hits against a baffle and from there slides on the conveyor.
  • a spread width setting may be further provided.
  • a particularly homogeneous discharge of the carrier material can take place, which can likewise lead to a homogeneous carrier with defined quality.
  • a scattering head or two, three or more scattering heads can be provided.
  • the carrier can be particularly tailor-made in a particularly simple manner, for example by providing a desired material mixture.
  • the mixture can be easily adapted during the manufacturing process or between batches, so that a particularly large variability can be ensured.
  • a mixture for the carrier material can be generated only immediately before processing, so that a negative influence on the various components with each other and a consequent reduction in the quality of the carrier produced can be prevented.
  • a shaping of the carrier material arranged between the band-like conveying means takes place under the action of temperature or heat.
  • this process step takes place by the acting heat or heat thus melting or softening of Support material or at least a part thereof, whereby, for example, the granules can be formed.
  • it can homogeneously fill the receiving space forming between the conveying means and thus form a web-shaped carrier which can be further treated.
  • the thus formed web-shaped carrier can be compressed according to method step d) below.
  • This process step can be carried out in particular in a suitable press or roller. There is thus here a first compression of the web-shaped carrier.
  • the carrier can already essentially obtain its desired thickness, so that in the following processing steps only a slight compression needs to take place and thus the further steps can be particularly gentle, as will be explained in detail below.
  • it can be ensured, in particular, that the temperature of the carrier has cooled down so far that a suitable compressibility can be achieved while maintaining the desired result.
  • a further treatment of the carrier takes place under the action of temperature or heat and pressure, in particular using a two-band press.
  • the surface properties of the carrier can be adjusted in this method step.
  • a smoothing of the surface can take place.
  • the previously compressed carrier can be treated under the action of temperature and pressure, wherein in particular the pressure can be selected low such that this second compression takes place only in a very small range.
  • a compression in a range of ⁇ 5%, carried out in particular ⁇ 3% of the total thickness of the carrier before compression can be chosen in particular depending on a desired adjustment of the surface properties, which can be particularly gentle.
  • the use of a two-belt press may be advantageous, since particularly gentle compression steps are possible with such a press, and furthermore the surface quality can be adjusted in a particularly effective and defined manner.
  • the use of a belt press can enable high line speeds, so that the entire process can enable a particularly high throughput.
  • such a belt press which usually has a fairly long processing space in the conveying direction of the carrier, have a plurality of tempering zones, which may allow a temperature profile and thus an effective adjustment of the surface properties even at high line speeds.
  • a particularly uniform and defined adjustable belt tension of the two-band press can be made possible by the provision of pneumatic cylinders, for example, so that the adjustment of the surface quality as well as the compression can be particularly exact.
  • the belt press can include about steel bands and be tempered by a thermal oil heating.
  • Smoothing or adjusting the surface finish may mean in this step that, although the uppermost surface is smoothed, already introduced structures or pores, however, are not or only influenced within a defined range, so that they still remain in the desired manner after this process step may be present, insofar as this is desired.
  • This can be made possible in particular by the use of a belt press with a suitable temperature profile and with suitable pressure values.
  • cooling of the web-shaped carrier takes place in a further method step f).
  • the carrier can in particular by the provision of a
  • Cooling device can be cooled with defined cooling stages to a temperature which corresponds to the room temperature or is purely exemplary in a range of up to 20 ° C above. For example, there may be a plurality of cooling zones to allow for defined cooling of the support.
  • the carrier After cooling of the carrier produced, the carrier can first be stored in a web-like form or as an isolated plate-like carrier, and the process can initially be completed. Preferably, however, immediately follow further treatment steps, which may be feasible without grinding, in particular in order to process the provided support so as to produce a finished panel, as explained in detail below.
  • the method comprises the further following method steps in order to provide the support with a decoration and to coat it with a protective layer.
  • the subsequent steps are preferably carried out directly with the web-shaped carrier produced.
  • the web-shaped carrier is first subdivided into a plurality of plate-shaped carriers prior to one of method steps g) to j) and / or the plate-shaped carrier is further processed by the corresponding following method steps.
  • the following explanations apply to both alternatives, with a further discussion of treatment of the carrier for the sake of simplicity.
  • pretreatment of the carrier for electrostatic discharge can thus optionally first be carried out, for example, before process step g).
  • This may in particular serve to avoid the occurrence of blurring in the course of decor application.
  • This is particularly suitable for printing methods for applying the decorative layers, since the build up in the course of the production process electrostatic charge in the substrates to be printed to a deflection of the color or Drops of ink on their way from the print head to the surface to be printed. The thus caused inaccuracy of the ink application leads to the noticeable blurring of the printed image.
  • the means for discharging electrostatic charges may comprise at least one roller, brush or lip of a conductive material with a conductivity ⁇ 1 * 10 3 Sm -1 , which electrically conductively contacts the carrier at least in the area of the printing unit and which is connected to an electrical ground potential is.
  • the electrical ground potential can be provided for example by a ground.
  • a device for discharging electrostatic charges may be, for example, a device for generating a corona discharge.
  • a decorative substrate may furthermore optionally be applied to at least one partial region of the carrier.
  • a primer can be applied in particular for printing processes as a decorative substrate, for example in a thickness of ⁇ 10 ⁇ m to ⁇ 60 ⁇ m.
  • the primer used may be a liquid radiation-curing mixture based on a urethane or a urethane acrylate, optionally with one or more of a photoinitiator, a reactive diluent, a UV stabilizer, a rheology agent such as a thickener, radical scavenger, leveling agent, defoamer or preservative, pigment and / or or a dye.
  • the urethane acrylate can be contained in the form of reactive oligomers or prepolymers in the primer composition.
  • reactive oligomer or "prepolymer” is to be understood as meaning a compound comprising urethane acrylate units, which may be radiation-induced, possibly reactive to urethane polymer or urethane acrylate polymer with the addition of a reactive binder or reactive diluent
  • Urethane acrylates in the context of the invention are compounds which are essentially composed of one or more aliphatic structural elements and urethane groups.
  • Aliphatic structural elements include both Alkylene groups, preferably having 4 to 10 C-atoms, as well as cycloalkylene groups having preferably 6 to 20 C-atoms. Both the alkylene and the cycloalkylene groups may be mono- or polysubstituted with C 1 -C 4 -alkyl, in particular with methyl, and may contain one or more non-adjacent oxygen atoms.
  • the aliphatic structural elements are optionally connected to each other via quaternary or tertiary carbon atoms, via urea groups, biuret, urethdione, allophanate, cyanurate, urethane, ester or amide groups or via ether oxygen or amine nitrogen.
  • urethane acrylates according to the invention may also have ethylenically unsaturated structural elements. These are preferably vinyl or allyl groups which may also be substituted by C 1 -C 4 -alkyl, in particular methyl, and which are derived in particular from ⁇ , ⁇ -ethylenically unsaturated carboxylic acids or their amides. Particularly preferred ethylenically unsaturated structural units are acryloyl and methacryloyl groups such as acrylamido and methacrylamido and especially acryloxy and methacryloxy.
  • Radiation-curable in the sense of the invention means that the primer composition can be at least partially polymerized, induced by electromagnetic radiation of a suitable wavelength, such as, for example, UV radiation, or electron radiation.
  • urethane acrylates have the advantage of good adhesion both to the support material and to the decorative layer, ie the decorative color or ink. This is due inter alia to the polymerization reactions occurring in this type of polymers, in which on the one hand a radiation-induced radical polymerization of the OH groups occurs, on the other hand, a post-curing of the polymer via the NCO groups.
  • pre-structured carriers ie carriers whose surface already has a three-dimensional structuring, can be provided with a primer layer with the method according to the invention, which ensures that the subsequently applied decoration is adhesively bonded to the carrier.
  • the primer can preferably be applied in the process according to the invention by means of rubber rollers, casting machine or by spraying onto the carrier plate.
  • the primer is preferably used in an amount between ⁇ 1 g / m 2 and ⁇ 100 g / m 2 , preferably between ⁇ 10 g / m 2 and ⁇ 50 g / m 2 , in particular between ⁇ 20 g / m 2 and ⁇ 40 g / m 2 applied.
  • irradiation is carried out with a radiation source of suitable wavelength.
  • a primer it is possible to apply the decor to a decorative paper which can be printed with a corresponding decor, which can be provided as a connection means, for example, by means of a resin layer previously applied to the support.
  • a resin layer is suitable both for flexo printing, offset printing or screen printing methods, and in particular for digital printing techniques, such as inkjet method or laser printing method.
  • a resin composition having as a resin component at least one compound selected from the group consisting of melamine resin, formaldehyde resin, urea resin, phenol resin, epoxy resin, unsaturated polyester resin, diallyl phthalate, or mixtures thereof.
  • the resin composition may be, for example, in an application amount between ⁇ 5 g / m 2 and ⁇ 40 g / m 2 , preferably ⁇ 10 g / m 2 and ⁇ 30 g / m 2 are applied.
  • a paper or nonwoven having a grammage of between ⁇ 30 g / m 2 and ⁇ 80 g / m 2 , preferably between ⁇ 40 g / m 2 and ⁇ 70 g / m 2 may be applied to the plate-shaped carrier.
  • a decoration which imitates a decorative pattern can be applied to at least one subregion of the carrier.
  • the decor can be applied by the so-called direct printing.
  • direct printing refers to the application of a decoration directly to the support of a panel or to a non-printed fibrous material layer or a decorative substrate applied to the support.
  • Different printing techniques such as flexographic printing, offset printing or screen printing can be used.
  • digital printing techniques for example, inkjet method or laser printing method can be used.
  • the decor can be applied identical to a template.
  • the three-dimensional decor data can be provided by a three-dimensional scanning of the decor template by means of electromagnetic radiation, for example by a three-dimensional scanner (3D scanner).
  • a plurality of decorative layers with at least partially different surface application based on provided three-dimensional decor data can be applied successively.
  • the decorative layers can be formed from a particular radiation-curable ink and / or ink.
  • a UV-curable ink or ink may be used.
  • a particularly detailed and consistent replica of the decorative template can be achieved.
  • a Synchronous pore can be in particular a pore or a different type of structure, which is spatially arranged exactly where it is optically represented by a matching with the optical decor features haptic structuring. This is essentially the case automatically in this refinement, since the structural design is precisely produced by the ink or ink.
  • decor templates such as wood-based panels
  • this color impression or color gradient can be modeled in particular detail in this embodiment, which also makes the overall impression of the panel appear even more identical.
  • the ink or ink used is radiation-curable, a particularly rapid solidification can be achieved, as a result of which the plurality of layers can be rapidly applied to one another, which can also make the overall process feasible in a shorter time and thus more cost-effective.
  • the term radiation-curable ink is understood to mean a composition containing binder and / or filler as well as color pigments, which can be at least partially polymerized induced by electromagnetic radiation of suitable wavelength, such as UV radiation or electron radiation.
  • the term radiation-curable ink is to be understood as meaning a substantially filler-free, color pigments-containing composition which can be at least partially polymerized induced by electromagnetic radiation of suitable wavelength, such as UV radiation or electron radiation.
  • the decorative layers can each be applied in a thickness in a range of ⁇ 5 ⁇ m to ⁇ 10 ⁇ m.
  • a color and / or structure positive image also apply a corresponding negative image of the decor template.
  • the color impression of, for example, a grain can be reversed by the use of digital data, so that a negative arises with respect to the color or, in particular, lighter and darker areas.
  • the same is possible in addition to the color impression also for the applied structure, so that also with respect to the structural design, a negative is feasible. Even such effects can be easily integrated into a production process on the basis of digital three-dimensional data without any lead time or conversions.
  • a coating of a protective layer on at least a portion of the decoration may be provided.
  • a layer for protecting the applied decoration can be applied in particular as a wear or cover layer above the decorative layer in a subsequent process step, which in particular protects the decorative layer from wear or damage by dirt, moisture or mechanical effects such as abrasion.
  • the wear and / or cover layer is laid on the printed support as a pre-produced overlay layer, for example based on melamine, and connected thereto by pressure and / or heat.
  • a radiation-curable composition such as, for example, a radiation-curable lacquer, such as an acrylic lacquer, is also applied to form the wear and / or cover layer.
  • the wear layer hard materials such as titanium nitride, titanium carbide, silicon nitride, Silicon carbide, boron carbide, tungsten carbide, tantalum carbide, alumina (corundum), zirconium oxide or mixtures thereof, to increase the wear resistance of the layer.
  • the application can be applied for example by means of rollers, such as rubber rollers or by means of pouring devices.
  • cover layer can first be partially cured and subsequently a final coating with a urethane acrylate and a final curing, such as with a gallium radiator, are performed.
  • the cover and / or wear layer may include means for reducing the static (electrostatic) charge of the final laminate.
  • the cover and / or wearing layer compounds such. Choline chloride has.
  • the antistatic agent may, for example, in a concentration between ⁇ 0.1 wt .-% and ⁇ 40.0 wt .-%, preferably between ⁇ 1.0 wt .-% and ⁇ 30.0 wt .-% in the cover and / or composition for forming wear layer.
  • a structuring in particular a surface structuring matching the decor
  • the carrier plate already has a structuring and alignment of a printing tool for applying the decor and the support plate to each other in dependence on by means of the optical process detected structuring of the support plate.
  • a necessary relative to the orientation relative movement between the pressure tool and support plate to each other by a displacement of the support plate or by a displacement of the pressure tool.
  • a structuring of Decorative panels after the application of the cover and / or wear layer takes place.
  • a curable composition is applied as cover and / or wear layer and a curing process takes place only to the extent that only partial hardening of the cover and / or wear layer takes place.
  • a desired surface structure is impressed by means of suitable tools, such as a hard metal structural roll or a stamp.
  • the embossing is done in accordance with the applied decor.
  • a matching with the decor surface structuring is introduced.
  • the surface of the decorative panel has a haptic perceptible structure, which corresponds in shape and pattern of the applied decor, so as to obtain a true to the original reproduction of a natural material also in terms of haptics.
  • a counter-pull can be applied on the side opposite the decorative side. It is particularly preferred that the counter-pull is applied in a common calendering with the paper or non-woven on the decorative side.
  • the edge regions of the panel can be structured or profiled, in order to provide in particular detachable connecting elements.
  • a profiling according to the invention that by means of suitable material removal tools at least in a part of the edges of the decorative panel a decorative and / or functional profile is introduced.
  • a functional profile is understood, for example, to mean the introduction of a tongue and / or groove profile into an edge in order to make decorative panels connectable to each other via the introduced profilings.
  • elastic materials are advantageous, since such profiles alone can be produced by them, which are particularly easy to handle and stable. In particular, no further materials are necessary to produce the fasteners.
  • the method described above enables an improved production of a wall panel or floor panel.
  • the support material can be chosen particularly freely and, in particular, support materials can be used which can have particularly advantageous properties for the panel to be produced.
  • support materials can be used which can have particularly advantageous properties for the panel to be produced.
  • the method for producing a carrier that can be used in the method for producing a wall and floor panel can be advantageous, in particular in the context of the present inventive method for producing wall and floor panels, since it enables particularly high line speeds, which far exceed those of the prior art Line speeds known to the art, as a feed rate of the carrier or the conveying means, may be for the manufacture of a panel.
  • Line speeds of up to 15 m / min can be achieved, in particular by the use of a two-belt press, whereby values of 6 m / min or more can also be possible for materials which are problematic in this respect.
  • a very accurate thickness can be achieved, in particular for panel support materials, wherein, for example, thickness tolerances in a range of 0.1 mm or less can be achieved.
  • a carrier produced by the above-described method can furthermore have a particularly uniform thickness, which allows a particularly defined and reproducible product and thus a particularly high quality.
  • a carrier material based on a plastic or a wood-plastic composite material can be provided.
  • the carrier plate may be formed of a thermoplastic, elastomeric or thermosetting plastic.
  • recycled materials from the materials mentioned can be used in the context of the method according to the invention.
  • thermoplastic materials such as polyvinyl chloride, polyolefins (for example polyethylene (PE), polypropylene (PP), polyamides (PA), polyurethanes (PU), polystyrene (PS), acrylonitrile-butadiene-styrene (ABS), polymethyl methacrylate may be preferred as the plate material (PMMA), polycarbonate (PC), polyethylene terephthalate (PET), polyetheretherketone (PEEK) or mixtures or co-polymers thereof
  • PMMA plate material
  • PC polycarbonate
  • PET polyethylene terephthalate
  • PEEK polyetheretherketone
  • % to ⁇ 20% by weight in particular ⁇ 10% by weight, preferably ⁇ 7% by weight, for example in a range from ⁇ 5% by weight to ⁇ 10% by weight about the under the trade name "Dinsch" of the BASF sold plasticizers.
  • copolymers such as acrylates or methacrylates may be provided.
  • thermoplastics also offer the advantage that the products made from them can be recycled very easily. Recycled materials from other sources can also be used. This results in a further possibility for reducing the production costs.
  • Such carriers are very elastic or resilient, which allows a comfortable impression when walking and also can reduce the noise occurring when committing compared to conventional materials, thus an improved footfall sound can be realized.
  • the above-mentioned carriers offer the advantage of good water resistance since they have a swelling of 1% or less. This is true in a surprising way in addition to pure plastic substrates for WPC materials, as they are explained in detail below.
  • the carrier material may comprise or consist of wood-polymer materials (WPC).
  • WPC wood-polymer materials
  • a wood and a polymer may be suitable, which may be present in a ratio of 40/60 to 70/30, for example 50/50.
  • Polypropylene, polyethylene or a copolymer of the two abovementioned materials can be used as polymer constituents.
  • Such materials offer the advantage that they can already be formed into a support at low temperatures, such as in a range of ⁇ 180 ° C. to ⁇ 200 ° C., in the method described above, so that particularly effective process control, for example at exemplary line speeds in a range of 6m / min, can be made possible.
  • a WPC product with a 50/50 distribution of wood and Polymer shares with an exemplary product thickness of 4.1mm possible, which can enable a particularly effective manufacturing process.
  • very stable panels can be produced which furthermore have high elasticity, which can be advantageous in particular for an effective and cost-effective design of connecting elements on the edge region of the carrier and furthermore with regard to footfall sound insulation.
  • the aforementioned good water compatibility can be made possible with a swelling of less than 1% in such WPC materials.
  • WPC materials for example, stabilizers and / or other additives, which may preferably be present in the plastic content.
  • the carrier material comprises or consists of a PVC-based material.
  • PVC-based carrier materials can be used in a particularly advantageous manner for high quality panels, which are easily used even in wet rooms.
  • PVC-based carrier materials are also suitable for a particularly effective production process, since here line speeds of 8 m / min with an exemplary product thickness of 4.1 mm may be possible, which may allow a particularly effective production process.
  • such carriers have an advantageous elasticity and water compatibility, which can lead to the aforementioned advantages.
  • mineral fillers may be advantageous. Particularly suitable here are about talc or calcium carbonate (chalk), alumina, silica, quartz, wood flour, gypsum.
  • talc or calcium carbonate (chalk) alumina
  • silica silica
  • quartz silica
  • wood flour gypsum
  • chalk can be provided in a range from ⁇ 30% by weight to ⁇ 70% by weight, it being possible in particular for the slips of the carrier to be improved by the fillers, in particular by the chalk.
  • they can be colored in a known manner.
  • the plate material has a flame retardant.
  • the carrier material may comprise hollow microspheres.
  • Such additives can in particular cause the density of the carrier and thus of the panel produced can be significantly reduced, so that a particularly simple and cost-effective transport and also a particularly comfortable installation can be guaranteed.
  • a stability of the panel produced can be ensured in particular by the insertion of hollow microspheres, which is not significantly reduced compared to a material without hollow microspheres.
  • stability is sufficient for most of the applications.
  • Under hollow microspheres can be understood in particular structures that have a hollow body and have a size or a maximum diameter, which is in the micrometer range.
  • usable hollow spheres may have a diameter which is in the range of ⁇ 5 ⁇ m to ⁇ 100 ⁇ m, for example ⁇ 20 ⁇ m to ⁇ 50 ⁇ m.
  • a material of the hollow microspheres is basically any material into consideration, such as glass or ceramic.
  • due to the weight of plastics, such as the plastics used in the support material, for example PVC, PE or PP, may be advantageous, which may optionally be prevented, for example by suitable additives, from deforming during the manufacturing process.
  • the band-like conveying means may be at least partially structured.
  • structured conveying means it is possible to produce a carrier which is likewise structured and thus can have pores, for example, which can reflect a natural product to be sensed.
  • the structuring or in this embodiment the pores can be realized in one working step with the shaping of the band-shaped carrier, so that a further working step for the formation of the pores can be dispensed with.
  • the introduced structure in that it is already present in the carrier and thus in the core of the panel, even with the highest stress be particularly stable and durable.
  • the conveyor belts can also have a defined roughness, since such a venting can be improved in a shaping of the carrier.
  • different roughness depths can be used for the upper and lower band, wherein the lower band can have a greater roughness depth than the upper band or band-like conveying means.
  • the lower band and / or the upper band may have a roughness depth in a range of ⁇ 0 to ⁇ 25 ⁇ m.
  • a sensor for checking the arrangement of the carrier material between the two belt-like conveying means may be provided.
  • the sensor may detect the placement of the substrate on the lower conveyor.
  • the sensor may have a feedback to the scattering units so as to be able to react immediately to a faulty application.
  • the sensor can be shielded by appropriate fenders to prevent accidental leakage of X-rays.
  • a cooling system can be provided to protect and extend the life of the sensor.
  • a fiber material can be incorporated into the carrier.
  • the fiber material can be incorporated into the carrier in process step b).
  • a fiber material in particular as a fiber material web, be wound on a roll and unwound by means of a unwinding for unwinding of the fiber material and between the two belt-like conveyor are guided to insert the fiber material.
  • a glass fiber fleece can be used.
  • a carrier can be produced with a particularly high load-bearing capacity or stability, since the strength of the carrier can be significantly increased by the incorporated fiber material.
  • the carrier can be particularly tailored in this embodiment, since, for example, by providing a plurality of scattering units, as explained above in detail, the carrier material, for example, above and below the web can be adjusted as desired. Furthermore, a still tailor-made solution can be made possible by the provision of a plurality of fibrous material webs, wherein the carrier material can in turn be variable or adaptable as desired.
  • a temperature gradient can be set in method step c).
  • a temperature gradient can be set along a conveying direction of the carrier material.
  • this method step can enable a particularly high-quality product and also allow a particularly high line speed.
  • a particularly rapid heating can be made possible, which allows a high line speed. This can be realized, for example, by a comparatively higher temperature in a first or front region in the conveying direction. In this case, too high a temperature effect on the carrier material can continue to be prevented, which can prevent damage and enable a particularly high quality.
  • a degassing can be improved and accelerated upon heating of the support material, which in turn allows a high line speed and also can provide a particularly high stability and quality by preventing gas inclusions.
  • This can be made possible in particular by a temperature gradient in a direction perpendicular to the conveying direction. In the latter case, in particular, the area below the substrate can be higher be heated than the area above the substrate. For example, here a temperature gradient in a range of 50 ° C may be advantageous.
  • method step c) can be carried out using two plate-like shaping devices.
  • a particularly long processing time and shaping of the carrier take place even at high line speeds, which may allow a particularly defined forms of the carrier.
  • the carrier material For in particular in this embodiment can be easily heated to a desired and necessary temperature even at high line speeds by a long contact time of the carrier material with the plate-like shaping devices, which can be heated accordingly, the carrier material.
  • the formation of temperature profiles can be made particularly simple and effective.
  • process step d) is carried out using an S-roll.
  • an S-roll as a compression unit, desired compression can be enabled with a simple and inexpensive means defined even at high line speeds.
  • the roller can be adjustable, for example, in the direction of the continuous carrier material.
  • the S-roll for example, only comprise a roller which exerts a force only in combination with a counterforce by the belt tension of the conveyor.
  • one or a plurality of counter-rollers may be provided, which apply the corresponding counterforce.
  • an S-roll can be understood to mean a roll which is arranged such that the support circulates in an S-shaped manner, as is known to the person skilled in the art and described in detail below with reference to the figures.
  • the carrier can be compressed in step e) by a factor of> 0% to ⁇ 7%, preferably> 0% to ⁇ 5%.
  • method step e) can thus obtain a particularly smooth surface by means of a slight compression, since this method step can essentially be tuned to the smoothing or to the setting of the surface quality.
  • the entire structure of the press, in particular the dual-band press can be aligned with smoothing and there is no need to focus on excessive compression, which can produce a particularly good surface image even at high throughputs.
  • the invention relates to a device for producing a decorated wall or floor panel, which is characterized in that the device comprises means for performing a method configured as described above.
  • the device comprises means for performing a method configured as described above.
  • the invention relates to a wall or floor panel, produced according to a method described above, wherein a plate-shaped carrier has a profiling at least in one edge region.
  • a profiling according to the invention it is provided that a decorative and / or functional profile is introduced by means of suitable material-removing tools at least in a part of the edges of the decorative panel.
  • a functional profile for example, the introduction of a tongue and / or groove profile in an edge to understand decorative panels on the introduced Profiles connectable to each other.
  • a decorative profile in the sense of the invention is, for example, a chamfer introduced in the edge region of the decorative panel in order to simulate, for example, a joint between two interconnected panels, as occurs, for example, in so-called plank flooring.
  • the decorative profile to be provided in a panel such as a chamfer
  • the functional profile for example tongue and groove
  • the decor also corresponds to the desired imitation of a natural material, for example, in the areas of the profiling in a detailed manner.
  • the print template used for printing in the area of the profiling of the panel can be distortion-compensated.
  • Distortion compensation means in the context of the invention for example, for the exemplary case of application with a printing process, which is compensated by the deviation of the profiling from the surface plane of the carrier, for example at a chamfer flank, caused distortion of the printed image by adjusting the artwork to the deviation. It may be provided, for example, that the compensation of the distortion by means of adaptation the pixel spacing, the pixel size and / or the color order depending on the intended edge profile of the finished decorative panel.
  • the triggering of the print head can be effected as a function of the distortion to be compensated, so that the print head is deflected beyond the profiled area, for example, and the color output is adapted to the profile.
  • the joints such as V-joints
  • the decorative layer is applied to the carrier profiled in this way and the carrier is then divided at least in the profiled areas.
  • the type of division such as, for example, sawing, laser cutting or water jet cutting, it can preferably be provided that the required cutting allowance in the introduced profile is taken into account.
  • the plate-shaped carrier may comprise a material based on a WPC material or a PVC material.
  • a WPC material or a PVC material.
  • the process can have further process steps in order to obtain the finished wall or floor panel.
  • the device 10 according to FIG. 1 comprises first two circumferential band-like conveying means 12, 14 which are guided in particular by deflection rollers 16 such that between them a receiving space 18 for receiving and processing a provided pourable, in particular granular carrier material 20, such as based on a plastic, such as PVC, or a wood-plastic composite material, such as wood and PP, PE or a block copolymer comprising PP and PE, forms.
  • the conveying means 12, 14 may be at least partially made of polytetrafluoroethylene be, for example, be coated with it.
  • the conveying means 12, 14 may be at least partially roughened or structured, in particular on their side facing the receiving space 18. Further, the conveying means 12, 14 may have a width in a range of about 1.5 m.
  • a discharge unit 22 is provided with one or a plurality of discharge heads 24, by means of which the carrier material 20 can be arranged on the lower conveying means 14.
  • the discharge heads 24 may in this case comprise a funnel 25, which applies the carrier material 20 to corresponding scattering rollers 26, whereupon the carrier material 20 can be scattered onto the lower conveying means 14.
  • a sensor for checking the arrangement of the carrier material 20 between two belt-like conveying means 12, 14 may be provided.
  • the sensor may in particular be coupled to the discharge unit 22 in order to directly correct a potentially inaccurate filling of the receiving space 18.
  • vibrators may also be provided. These can act approximately on the lower conveyor 14 and be arranged, for example, under the lower conveyor 14, so that the carrier material 20 is finely distributed.
  • a device for introducing a fiber material into the receiving space 18 and thus be provided in the carrier can be designed like a belt and unwound from a roll.
  • the fiber material may be arranged approximately between two discharge heads 24 in order, for example, to be able to arrange a different material above and below the fiber material.
  • the fiber material can be introduced, for example, such that above and below the fiber material, a desired amount of support material 20 is located.
  • a forming unit 28 is further provided, which is adapted to the carrier material 20 under the action of temperature or heat to fuse the carrier material 20 to form a web-shaped carrier 36 to shape.
  • the molding unit 28 can have approximately two plate-like molding devices 30, 32, which can be heated by a heating device 34, for example by means of a thermal oil.
  • the support material 20 may be heated until, depending on the melting point of the support material 20 or a part thereof, a temperature of, for example and depending on the material used, such as PVC or a WPV material, ⁇ 180 ° C to ⁇ 200 ° C has reached.
  • the molding unit 28 or the molding devices 30, 32 can be heated, for example to a temperature of up to 250 ° C.
  • one or a plurality of independently adjustable heating areas can be provided for setting a temperature gradient.
  • the entire shaping devices 30, 32 which may have a length of several meters, may be heatable, or only part of them may be heatable.
  • the molding unit 28 may in particular have a parallel gap, which may be formed by the plate-like molding devices 30, 32.
  • an inlet mouth can be provided at the inlet by a conical shape to an improved inlet of the carrier material 20.
  • the force acting on the carrier material 20 may be fed in a range from> 0 kg / m 2, up to ⁇ 1 kg / m 2.
  • a uniform pressurization without the provision of a pressure profile or a pressure gradient can be provided.
  • the lower former 32 is longer than the upper former 30 and also begins before the upper. It can thereby be achieved that processing only takes place when the carrier material 20 has already been melted or at least melted on and at least partially softened. As a result, a particularly defined shaping process can be made possible.
  • the pressing device 38 may for example comprise an S-roll, which in detail in the FIG. 2 is shown.
  • the S-roll can be moved substantially perpendicular to the surface of the carrier 36 and thus to the direction of travel of the carrier 36, as indicated by the arrow 58, so that the desired pressures can be particularly advantageous adjustable.
  • the pressing device 38 may, for example, on the carrier 36 exert a pressure that may be in a range of ⁇ 1kg / m 2 to ⁇ 3kg / m 2 .
  • the S-roll comprises a main roller 60, which acts on the web-shaped carrier 36.
  • the belt tension may be sufficient as a back pressure, but it is preferred that at least one counter-pressure roller 62 is provided.
  • two pairs of calender rolls 64 and, optionally, deflection rolls 66 can also be provided, which can furthermore provide for a suitable strip tension.
  • the main roller 60 may be wrapped by the sheet-shaped carrier 36 in a range of about 50% or more.
  • the temperature of the carrier 36 In addition, in the case of an inlet into the pressing device 38, in particular, the temperature present at the exit from the forming unit 28 corresponds.
  • the carrier 36 is subsequently guided to a further pressing device 40.
  • another heater 42 such as an IR heater, may be provided between the press devices 38, 40.
  • this advantageously can be a two-belt press, which in particular can have steel belts 44, 46 and wherein the belts 44, 46 of the two-belt press can be guided by deflection rollers 48, 50.
  • the deflection rollers 48, 50 can be heated, for example by means of a thermal oil heater and / or the rollers on the same side of the gap can be arranged approximately a distance in a range of ⁇ 1m to ⁇ 2m, for example 1.5m from each other, wherein the Bands 44, 46 may have a width in a range of about 1.5m.
  • the carrier 20 located between the conveying means 12, 14 is guided between the deflection rollers 48, 50 and thus between the belts 44, 46, in particular steel belts.
  • each pressing and / or heating means 52, 54 are provided on the carrier 36 opposite side of the bands 44, 46.
  • These can both the conveyors 12, 14 and thus the carrier 36 both heat, as well as slightly compress.
  • an air heater may be provided and a plurality of rollers, which may allow an intermittent pressing.
  • a temperature in a range of up to 250 ° C act on the carrier 36.
  • the temperature may be in a range from ⁇ 25 ° C to ⁇ 35 ° C above the melting temperature or softening temperature of the support material or a part thereof.
  • such a pressure on the support 36 can act, that the carrier 36 is compressed at step e) by a factor of ⁇ 7.5%, preferably ⁇ 5%, for setting in a range of 0.2 mm to ⁇ ⁇ 0,1mm ,
  • the pressing and / or heating devices 52, 54 may occupy substantially the entire area between the deflection rollers 48, 50, or even a limited area along the conveying direction.
  • the carrier After passing through the pressing device 40, the carrier may have a temperature in the range of approximately 190 ° C.
  • the pressing device 40 may have a variable pressure profile, starting approximately with 6mm and ending with 4.1mm, or advantageously designed as an isochronous press.
  • a cooling device 56 is arranged, through which the carrier can be cooled to a temperature which is for example in a range of ⁇ 35 ° C.
  • the cooling device 56 may be based, for example, on a water cooling system and include a plurality of cooling zones, in order to allow a defined cooling using precisely customizable cooling programs.
  • the length of the cooling zone can correspond to the effective length of the pressing device 40. After the cooling device 56 may still be provided another cooling belt.
  • the support which may have a final thickness in a range of ⁇ 3 mm to ⁇ 5 mm, for example 4.1 mm, can be treated further directly, or be stored, for example as a web-shaped carrier 36 or as an already singly plate-shaped carrier.

Landscapes

  • Laminated Bodies (AREA)
EP13177453.1A 2013-07-22 2013-07-22 Procédé de fabrication d'un panneau mural et de sol décoré Withdrawn EP2829415A1 (fr)

Priority Applications (21)

Application Number Priority Date Filing Date Title
EP13177453.1A EP2829415A1 (fr) 2013-07-22 2013-07-22 Procédé de fabrication d'un panneau mural et de sol décoré
US14/419,798 US10059072B2 (en) 2013-07-22 2014-07-18 Method for producing a decorated wall or floor panel
MX2015017824A MX366767B (es) 2013-07-22 2014-07-18 Método para producir una pared decorada o panel de suelo.
JP2016528463A JP6333375B2 (ja) 2013-07-22 2014-07-18 化粧壁パネル又は化粧床パネルの製造方法
PT14739847T PT3024669T (pt) 2013-07-22 2014-07-18 Método para produzir um painel decorado de parede ou de piso
UAA201601637A UA115101C2 (uk) 2013-07-22 2014-07-18 Спосіб виготовлення декорованої стінової або підлогової панелі
EP18172580.5A EP3401115B1 (fr) 2013-07-22 2014-07-18 Procédé de fabrication d'un panneau mural ou de sol décoré
AU2014295241A AU2014295241A1 (en) 2013-07-22 2014-07-18 Method for producing a decorated wall or floor panel
BR112016000124-9A BR112016000124B1 (pt) 2013-07-22 2014-07-18 Método e dispositivo para produzir um painel de parede ou de piso decorado
EP14739847.3A EP3024669B1 (fr) 2013-07-22 2014-07-18 Procédé de fabrication d'un panneau mural et de sol décoré
KR1020167002249A KR102095082B1 (ko) 2013-07-22 2014-07-18 장식 벽 또는 바닥 패널의 제조 방법
PCT/EP2014/065509 WO2015011049A1 (fr) 2013-07-22 2014-07-18 Procédé de production d'un panneau mural ou de sol décoré
ES14739847.3T ES2687372T3 (es) 2013-07-22 2014-07-18 Procedimiento para la fabricación de un panel decorado de pared o de suelo
MYPI2015704445A MY177467A (en) 2013-07-22 2014-07-18 Method for producing a decorated wall or floor panel
KR1020187006238A KR20180028543A (ko) 2013-07-22 2014-07-18 장식 벽 또는 바닥 패널의 제조 방법
CN201480035168.4A CN105307869B (zh) 2013-07-22 2014-07-18 用于生产装饰墙壁或地板的方法
RU2016105441A RU2635043C2 (ru) 2013-07-22 2014-07-18 Способ получения декоративной стеновой или напольной панели
TR2018/12933T TR201812933T4 (tr) 2013-07-22 2014-07-18 Dekore edilmiş bir duvar veya zemin panelinin üretimi için yöntem.
CA2912978A CA2912978C (fr) 2013-07-22 2014-07-18 Procede de production d'un panneau mural ou de sol decore
PL14739847T PL3024669T3 (pl) 2013-07-22 2014-07-18 Sposób wytwarzania dekorowanego panelu ściennego lub podłogowego
CL2015003750A CL2015003750A1 (es) 2013-07-22 2015-12-29 Metodo para producir una pared decorada o panel de suelo

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
EP13177453.1A EP2829415A1 (fr) 2013-07-22 2013-07-22 Procédé de fabrication d'un panneau mural et de sol décoré

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EP2829415A1 true EP2829415A1 (fr) 2015-01-28

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EP3348418A1 (fr) 2017-01-11 2018-07-18 Akzenta Paneele + Profile GmbH Panneau de sol ou mural à surface structurée et décorée
EP3348419A1 (fr) 2017-01-13 2018-07-18 Akzenta Paneele + Profile GmbH Panneau de sol ou mural à surface structurée et décorée à base d'une plaque en fibrociment
EP3536517A1 (fr) 2018-03-09 2019-09-11 Akzenta Paneele + Profile GmbH Matériau support à base de minéraux pour panneaux muraux ou de plancher décorés
EP3543034A1 (fr) 2018-03-23 2019-09-25 Akzenta Paneele + Profile GmbH Plaque porteuse pour un panneau de paroi, de sol ou de plafond directement imprimés
EP3578384A1 (fr) 2018-06-05 2019-12-11 Akzenta Paneele + Profile GmbH Matériau porteur à base d'une composition de matière plastique et d'une composition de matière solide minérales pour panneaux muraux ou de sol décorés
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EP3222795B1 (fr) * 2016-03-23 2022-07-27 Li & Co AG Élement de revetement mural ou de sol
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