EP2935722A1

EP2935722A1 - Structural element for the formation of a floor and/or wall covering and method for the production thereof

Info

Publication number: EP2935722A1
Application number: EP13814559.4A
Authority: EP
Inventors: Claus Permesang
Original assignee: ArsRatio Holding GmbH
Current assignee: ArsRatio Holding GmbH
Priority date: 2012-12-21
Filing date: 2013-12-23
Publication date: 2015-10-28
Also published as: CN105121758A; CN105121758B; WO2014121879A9; DE102012112831A1; WO2014121879A1; US20150345154A1

Abstract

The invention relates to a structural element for the formation of a floor and/or wall covering having a decorative layer comprising at least one decorative element (4) and having a carrier layer connected to the decorative layer and provided for bearing on the floor or the wall. According to the invention, the carrier layer (13) has a cast material solidified in a moulding space (1), which forms the carrier layer (13), with direct attachment to the decorative layer. In a method for producing such a structural element, the at least one decorative element (4) is arranged in a mould adjoining a moulding space (1) forming the carrier layer (13), and a cast material which solidifies with attachment of the carrier layer (13) to the at least one decorative element (5) is introduced into the moulding space (1).

Description

bunq:

CONSTRUCTION ELEMENT FOR THE GROUNDING OF A FLOOR OR / AND WALL COVER AND METHOD FOR THE PRODUCTION THEREOF

The invention relates to a component for the formation of a floor or / and wall covering, with a decorative layer comprising at least one decorative element and a support layer connected to the decorative layer, intended to rest on the floor or the wall.

The invention further relates to a method for producing such a component.

EP 1 682 733 B1 describes such components, from which in each case with little effort produce floor and / or wall coverings and can be reduced for reuse of the components. The e.g. consisting of one or more tiles decorative layer is connected via an intermediate layer with the carrier layer, said intermediate layer is made in a the decorative layer and the carrier layer receiving mold in a formed between the two layers mold space. In one operation with the production of the intermediate layer integrally connected joint fillings and connecting elements are formed on the component with the intermediate layer. About the hook-shaped connecting elements, the components can be coupled together at their edges, which also provided from the material of the intermediate layer Fugenfüllungen provide a seal between the components. The massive, e.g. Carrier layers of the components formed using recycled plastic material ensure by their weight a stable support of the covering on a carrier base.

The invention has for its object to provide a new device of the type mentioned that, if suitable for the production of mobile ground and / or wall coverings can be produced with less effort than in the prior art.

The component according to the invention which achieves this object is characterized in that the carrier layer has a casting material solidified in a forming space forming the carrier layer with direct bonding of the carrier layer to the decorative layer.

Advantageously, according to the invention, an intermediate layer but rather the entire carrier layer is produced in a mold space of a molding tool not only as in the prior art, but directly under connection of the carrier layer to the decorative layer. The component consists only of the decorative and the carrier layer. The support layer forming, solidifying in the mold cavity casting material provides according to the invention for a direct connection between the two layers. The carrier layer is therefore no longer as in the prior art from a separately prefabricated plate member, but is at least in its outline completely formed by pouring the mold space. The carrier layer comprises the intermediate layer known from the prior art, the binding function of which it partly assumes with the connection to the decorative layer.

While the carrier layer could possibly be made entirely from the casting material, if necessary, a filling material is embedded in the casting material of the carrier layer in a particularly preferred embodiment of the invention. Advantageously, the filler material at least constant strength of the carrier layer significantly reduce the amount of casting material required for the production of the component.

While as filling material e.g. a solid plate to be embedded in the casting material would be considered, in a preferred embodiment of the invention filling material is introduced into the mold space in the form of a particle bed to be penetrated by the casting material. In the solidified casting material, the particles are then distributed more or less evenly and the casting material forms a matrix enclosing the particles.

Depending on requirements, the material composition of such particle charges may vary. As far as it depends essentially only on a filling function to reduce the amount of casting material required, for example, fine gravel or sand would be suitable. Is it next to one for the strength of the carrier layer decisive reinforcement or a high thermal conductivity, such as metal scrap could be used. Preferred fillers and reinforcing substances currently considered are plastics derived from recycling processes.

With the different material compositions, therefore, different product properties, such as e.g. Thermal insulation, thermal conductivity, load capacity, sound insulation, the component weight, heatability and other more connected. Such product properties can be adjusted for the first time directly in the production process in a simple manner by targeted use of different aggregates, with almost unlimited possibilities of variation exist.

In all cases, it is important that the bulk particles have such a nature that between the particles enough space for penetration of the casting material remains.

Alternatively or additionally, a filling made of strand material could be used, in particular for reinforcing purposes, wherein in particular a reinforcing grid is to be considered.

A reinforcing grid could be formed three-dimensionally out of the lattice plane so as to extend over a substantial portion of the height of the carrier ply.

Further, as reinforcing elements, the casting material comes three-dimensionally penetrating fibers, e.g. Steel fibers, glass fibers or carbon fibers into consideration, whereby such fibers can also be combined to form a reinforcing mat. Alternatively, a three-dimensional web is formed, which is penetrated by the casting material. If the web is tightly spun with low void fractions, and e.g. is a metal spun similar to a scouring sponge, a particularly large reinforcing effect can be achieved. For a more coarse mesh, it would be denbkar whose voids are filled with fine bulk, e.g. ground PU scrap or the like to fill.

As a casting material is mainly polyurethane into consideration. Optionally, a foamed (or foaming) plastic material, in particular polyurethane foam. In one embodiment with a three-dimensional reinforcing gutter, the amount of casting material required could be reduced by foaming, the three-dimensional reinforcement compensating for the reduction in the strength of the casting material associated with foaming.

It is understood that as with the aggregates, the casting material also has the chemical composition and physical parameters adapted to the desired product properties, and that compositions and parameters may vary and influence one another even during the manufacturing process. The manufacturing method according to the invention can thus be adapted with little effort to a large number of different product variants.

In the mold, the at least one decorative element can be held by spacer elements at a desired distance to a bottom of the mold space.

Preferably, the bottom of the mold is adjustable relative to the spacer elements, in particular continuously adjustable, so that when using the mold for the production of different components advantageously a constant total thickness of the different components can be maintained.

Said cavity can also serve for the molding of connecting elements, joint fillings and / or sealing elements to the component, wherein the Anformung preferably takes place in one operation with the formation of the carrier layer of the same casting material. Alternatively, a separate Anformung using separate casting material would be possible.

Suitably, the molding of connecting elements serving areas of the mold cavity are kept free of filler material. Alternatively, a suitable bulk filling to be penetrated by the casting material could also extend to these areas.

In one embodiment of the method, areas of the mold space to be kept free are delimited, for example, by means of a structure which can be penetrated by the casting material, in particular a network structure, against the filling material. The casting material is expediently introduced into the molding space via the said regions which are kept free, so that a bulk material is generated from the areas to be kept free from the areas to be kept free. Alternatively, however, the casting material can also be introduced in a reverse direction into a filling area, in particular a central region of the molding space.

It is understood that bulk material layers of different materials can be embedded in one and the same carrier layer of a component according to the invention. In addition, different casting materials come into consideration, which may be introduced with a time delay in the mold cavity.

The invention will be explained below with reference to embodiments and the accompanying, relating to these embodiments drawings. Show it:

1 is a partial perspective view of a mold for the manufacture of a device according to the invention,

2 shows the mold of Fig. 1 in a sectional side view,

3 is a sectional detail view of the mold of Fig. 1,

FIG. 4 is a rear perspective view of a device of the invention made by the mold of FIG. 1; FIG.

5 is a sectional side view of the device of Fig. 4,

6 is a detailed sectional view of the device of Fig. 4,

7 shows further sectional detail views of exemplary embodiments of components according to the invention,

8 shows the mold of FIG. 1 with inserted reinforcing grid, FIG.

9 shows the reinforcing grid of FIG. 1 with inserted fiberglass mat, FIG.

10 shows a device according to the invention produced by means of the mold of FIG. 9, FIG.

FIG. 1 shows detailed views of the component of FIG. 10, FIG.

12 is a perspective view of another, sensor-containing device according to the invention in an exploded view,

FIG. 13 shows the component of FIG. 8 in a rear view, and FIG

Fig. 14 shows the component of Fig. 8 in a sectional side view in an exploded view. 1 to 3 shown in the form of a mold for the production of a plate-shaped, the formation of a floor and / or wall covering serving component has a flat cavity 1, from the bottom 2, tapered spacer pins 3 protrude. On the spacer mandrels 3 a to be arranged in the mold cavity 1 decorative element 4 can be placed, which is a

Decor layer of the produced in the mold component forms. The level in the example shown bottom 2 of the mold space 1 could also be profiled.

The decorative element 4 may be e.g. to act a ceramic, plastic, natural stone, metal, wood or glass plate. Instead of a single decorative element, a plurality of plate-shaped decorative elements forming the decorative layer could also be arranged in the mold. It would also be possible to have a decorative layer composed of a multiplicity of irregularly shaped elements, e.g. a layer of pebbles. In extreme cases, the decorative layer is formed by a particularly decorative filler.

For producing a component shown in FIGS. 4 to 6, a filling material 5 is introduced into the flat mold space 1, which in the exemplary embodiment shown is a bed of particles, between which space for a filling material penetrating into the mold space 1 consists of at least one side to be initiated casting material.

As the filling material, e.g. crushed plastic waste into consideration. But would also be fine gravel, a glass bead, sand, crushed metal scrap, metal balls in different sizes for reasons of weight, possibly hollow balls and more.

The filler filling 5 does not completely fill the mold space 1. At the edge remain free areas 6 and 7, the Anformung of hook-shaped connecting elements 8 and 9 and a circumferential butt joint filling 10 on

Decorative element 4 serve. Alternatively, a filling of the areas 6 and 7 with surcharges would be possible.

As can be seen from FIGS. 2 and 3, lines 1 1 and 12 lead into the region 6 or 7 for supplying casting material so that the casting material initially fills the regions 6, 7 before it penetrates the filling material fill 5. Advantageously, it is prevented that filling material 5 reaches the areas 6, 7. Cables for the supply of cast material could also be elsewhere in the mold space Open, for example, in the central region of the mold cavity from the front and / or back of the mold ago.

As casting material, in the example described, preferably PU components solidifying in the mold space are introduced, which were mixed together shortly before being fed. One-component materials would also be possible.

The casting material conducted into the mold space and solidifying there completely penetrates the filler fill 5 before solidification and, after solidification, forms a matrix enclosing the particles of the fill. In addition to the formation of a solid carrier layer 13 of the component, the solidifying cast material also ensures a firm connection between the carrier layer 13 and the decorative element 4, so that a stable component is formed.

For demolding the plate-shaped component is lifted from the bottom 2 of the mold space 1, wherein the spacer mandrels 3 leave corresponding recesses 14 on the underside of the device, as shown in Figures 4 to 6 can be seen. The spacer mandrels 3 could serve as ejection elements in a first demolding phase.

The bottom 2 of the mold is adjustable with displacement of the bottom in the longitudinal direction of the spacer mandrels 3, so that regardless of the thickness of a decorative element 5 used a constant total thickness of the device can be maintained. Even edge side walls of the mold space could be adjustable, so that components with different edge dimensions can be produced.

7 shows sections of further exemplary embodiments of components whose carrier layers 13a, 13b, 13c have differently structured fillings embedded in the casting material.

In the carrier layer 13a fine aggregates such as sand or metal powder are embedded. A structure which can be penetrated with casting material, in particular mesh structure 17, delimits the region of the carrier layer 13a provided with aggregates against areas free from excess deposits. The net structure 1 7 is permeable to the casting material, but not for the aggregate material.

The carrier layer 13b contains coarse additions, for example of PU recycling, metal or stone material. In the carrier layer 13c metal balls are embedded. In existing recesses 14 c electrical contacts could intervene for a current flowing through the metal balls heating current.

In addition to hook-shaped connecting elements 8 and 9 and a peripheral to the decorative element 4 butt joint filling 10, a sealing projection 15 and a such a projection of an adjacent component receiving groove 1 6 are clearly visible in Fig. 7.

FIG. 8 shows a forming tool with a reinforcement 23 inserted into the forming space 1, in the example shown in the form of a steel grid. The reinforcement 23 is placed within the mold space 1 near the mold cavity bottom 2, wherein a bulk material 5 wraps around the reinforcement and protrude spacer mandrels 3 through the reinforcement.

According to FIG. 9, instead of a metal grid in the tensile load area, a mat mat 24, in the example shown a glass fiber mat, is introduced as reinforcement, which rests on the mold space bottom 2 of the mold space 1.

In the carrier layer 13 of a component shown in Fig. 10, manufactured in the mold of Fig. 9, both a material filling 5 and the glass fiber mat 24 are penetrated by casting material and the casting material provides u.a. for a solid bond between the filling 5 and the reinforcement 24th

A component shown in FIGS. 12 to 14 has an annular channel 18 open to the support side with a branch 19. The annular channel 18 connects production-related recesses 14th

In the annular channel 18 with the branch 19, a sensor carrier 20 with four in each case an opening insertable sensors 21 can be used. The sensor carrier 20 further comprises at least one plug element 22 which fits into a recess in one of the connecting elements 8 and / or 9.

The sensors may be, for example, those which detect loads on the component, temperatures and / or sound effects. In the manufacture of a floor covering, all sensors of the covering are networked with each other via the respective connector elements 22. For example, it is possible to detect activity frequencies, impermissible soil loads, and other parameters.

Further, in recesses 14, possibly each of the recesses 14, in the manner of the sensors 21, each engage a heating element. In this case, the heating elements can be connected to one another and from component to component via the branch 19 and the plug element 22 corresponding elements. Instead of a heating element which itself emits heat, an electrical contact which conducts a heating current through the carrier layer could also intervene.

Claims

claims:

1 . Component for the formation of a floor or / and wall covering, with a

at least one decorative element (4) comprising a decorative layer and one connected to the decorative layer, provided for resting on the floor or the wall support layer (13),

characterized,

in that the carrier layer (13) has a molding space (1) forming the carrier layer (13) and having cast material solidified to the decorative layer by direct connection of the carrier layer (13).

2. Component according to claim 1,

characterized,

in that a filling material (5) is embedded in the casting material of the carrier layer (13).

3. Component according to claim 2,

characterized,

in that the filling material (5) has particles distributed in the casting material.

4. Component according to one of claims 1 to 3,

characterized,

that the filling material forms a reinforcement.

5. Component according to claim 4,

characterized,

that the reinforcement comprises reinforcing strands, in particular a reinforcing grid.

6. The component according to claim 5,

characterized,

that the reinforcing grid is formed three-dimensionally out of the lattice plane and possibly extends over the entire height of the carrier layer (13).

7. The component according to one of claims 1 to 6,

characterized,

that the casting material is polyurethane and optionally comprises foamed polyurethane.

8. A method for producing a component for the formation of a floor or / and wall covering, wherein the component has a decor layer at least one decorative element (4) and a decorative layer connected to the decor layer, provided for resting on the floor or the wall support layer (13) .

characterized,

in that the at least one decorative element (5) is arranged in a molding tool adjacent to a forming space (1) forming the carrier layer (13) and in that the forming space (1) is connected to the at least one decorative element (5) by connecting the carrier layer (13). solidifying casting material is introduced.

9. The method according to claim 8,

characterized,

in that a filling material (5) to be embedded in the casting material is introduced into the molding space (1).

10. The method according to claim 9,

characterized,

that the filling material (5) is introduced in the form of a particle bed to be penetrated by the casting material.

1 1. Method according to one of claims 8 to 10,

characterized,

the at least one decorative element (5) is held by spacer elements (3) at a desired distance from a bottom (2) of the mold space (1).

12. The method according to any one of claims 8 to 1 1,

characterized,

in that the mold space (1) also serves for the molding of connecting elements (8, 9), joint fillings (10) or / and sealing elements (15, 16) on the component.

13. The method according to claim 12,

characterized, in that the regions (6, 7) of the molding space (1) serving to form connecting elements (8, 9), joint fillings (10) and / or sealing elements (15, 16) are kept free of filling material (5).

14. The method according to claim 13,

characterized,

the freely held regions (6, 7) of the molding space (1) are delimited by means of a structure (1 7) which can be penetrated by the casting material, in particular network structure, against the filling material (5).

15. The method according to claim 13 or 14,

characterized,

the casting material is introduced into the molding space (1) via at least one of the areas (6, 7) or / and into a central area of the molding space (1).