EP3235970B1 - Plate-shaped building element - Google Patents

Plate-shaped building element Download PDF

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Publication number
EP3235970B1
EP3235970B1 EP17158827.0A EP17158827A EP3235970B1 EP 3235970 B1 EP3235970 B1 EP 3235970B1 EP 17158827 A EP17158827 A EP 17158827A EP 3235970 B1 EP3235970 B1 EP 3235970B1
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EP
European Patent Office
Prior art keywords
layer
plate
shaped component
component according
carrier layer
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.)
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Application number
EP17158827.0A
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German (de)
French (fr)
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EP3235970A1 (en
Inventor
Guido Schulte
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Individual
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Individual
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Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/02—Flooring or floor layers composed of a number of similar elements
    • E04F15/02038—Flooring or floor layers composed of a number of similar elements characterised by tongue and groove connections between neighbouring flooring elements
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/02—Flooring or floor layers composed of a number of similar elements
    • E04F15/02177—Floor elements for use at a specific location
    • E04F15/02188—Floor elements for use at a specific location for use in wet rooms
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/02—Flooring or floor layers composed of a number of similar elements
    • E04F15/10—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials
    • E04F15/102—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials of fibrous or chipped materials, e.g. bonded with synthetic resins
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/02—Flooring or floor layers composed of a number of similar elements
    • E04F15/10—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials
    • E04F15/107—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials composed of several layers, e.g. sandwich panels

Definitions

  • the invention relates to a plate-shaped component, in particular a floor panel.
  • Surface coverings especially in the form of floor coverings, are available in a wide variety of embodiments. Widely used are plate-shaped components, in particular floor panels in the form of laminate or parquet, with carrier plates of compacted fibers. Resilient floor coverings are known in the form of PVC coverings, linoleum coverings or as cork coverings.
  • the DE 10 2013 113 478 A1 discloses a panel having a support plate and a top-side wear layer.
  • the carrier plate consists of a composite material of fibers and a hydraulic binder.
  • the wear layer consists of a natural material-reinforced plastic. The carrier plate and the wear layer are hot-pressed together.
  • EP 2 523 804 B1 includes a method of making a wear resistant topsheet of the prior art.
  • a dry powder layer of a mixture of digested fibers, a binder, pigments and wear-resistant particles is applied to a support and then the mixture is cured to a pale-colored, wear-resistant layer using heat and pressure.
  • a floor covering the state of the art has a decorative layer, which consists of a pulp paper, which is impregnated with polyurethane. On the decorative layer, a wear layer is provided.
  • the flooring also has a core and a backing layer.
  • the decorative layer, core and back layer are each made of polyurethane.
  • the DE 1 715 436 U discloses a structural element for a floor covering.
  • the device consists of a composite plate of a cover layer, which is connected to an insulating layer.
  • the cover layer may be hard or elastic and, for example, made of natural or artificial stone, as well as made of wood.
  • the insulating layer should be hard and pressure-resistant and consist for example of stone or glass wool or plastic.
  • the cover layer and the insulating layer are connected via a tabulation layer.
  • DE 296 20 751 U1 illustrates a composite panel having at least two layers, namely a backing layer of natural and plastic materials and a cover layer of native and / or synthetic fibers.
  • a tile which consists essentially of a plant material, which are mixed with a thermosetting binder.
  • Subject of the DE 199 44 399 A1 is a floor element with a carrier layer and at least one on one side arranged on this and firmly connected to it cover layer.
  • the carrier layer is formed of polyurethane or acrylate as a binder and fillers disposed therein.
  • Elastic floor coverings are also in the EP 2 907 655 A1 as well as the EP 1 938 963 B2 described.
  • a generic plate-shaped component is further from the EP 2 777 928 A1 known.
  • the invention has for its object to provide a manufacturing and application technology improved plate-shaped component with very good installation and use properties, especially a floor panel show.
  • the plate-shaped component has an upper layer and a carrier layer. These are connected in one unit.
  • the upper layer consists of a mixture of fibrous and / or powdered wood material, binders and color pigments, which is pressed under the effect of temperature and pressure.
  • This top layer is characterized by special properties: it is highly resistant to abrasion, comparable to laminate flooring, but in contrast to such coverings, it can be made more homogeneous in its basic structure and in larger layer thicknesses. In addition, very scratch-resistant and durable like tiles or natural stone coverings, but clearly haptically more pleasant and with body contact / barefoot walking much warmer than tile coverings.
  • the carrier layer is formed on the basis of polyurethane.
  • the carrier layer thus consists of polyurethane binders (one- or two-component) and fillers or consists for the most part of polyurethane-based binders and fillers.
  • One aspect in this case is the use of two components of a polyurethane and also fillers such as chalk, talc, mineral fillers, optionally also cellulose as fillers, pigments and foaming agents or pore formers. Also provided are additives and stabilizers.
  • the polyurethane components or polyurethane binders may also at least partially made of recycled products, ie recycled polyurethane and in fiber or cubic form, z. B. as polyurethane foams or fraying chips. Particularly useful are polyurethane components, which consist of renewable raw materials, such as polyols from various vegetable oils.
  • the polyurethane of the carrier layer can be synthesized from an aromatic polyol. These are biogenic polyols, which are obtained from renewable raw materials. It is also possible to produce the polyurethane from an aliphatic polyol.
  • the carrier layer may also contain, in addition to polyurethane fillers, additives and / or dyes. These are mixed into the carrier material forming the base layer. About the fillers and / or additives the visual properties, in particular their elasticity and strength can be adjusted. Dyes are used to color the backing layer.
  • the top layer and the carrier layer can initially be manufactured separately and then glued together.
  • the top layer and the carrier layer can be pressed together.
  • One aspect of the invention provides for the compression of the top layer and carrier layer in a short-cycle press.
  • An essential aspect of the invention is the upper layer, which is formed from a mixture of fibrous and / or pulverulent wood material, binders and color pigments. This mixture is pressed under the influence of temperature and pressure. The pressing process takes place between a lower press plate and an upper press plate in a heated press. The pressed mixture alone can form the upper layer.
  • the upper layer is a thermoset processed composite material which is formed from different proportions of fibrous and / or pulverulent wood material and binder in the form of plastics and additives or color pigments. Also thermoplastic raw materials or thermoplastic components may be included in the manufacturing process and embedded / melted in the cured top layer.
  • the mixture of fibrous and / or pulverulent wood material, binders and color pigments is also referred to as a powder mixture in the context of the invention. Wood fibers contained in the powder mixture have a length of up to 500 ⁇ m.
  • the proportion of wood material in the mixture is at least 30%.
  • the proportion of wood material and or wood-based recyclates in the mixture is over 30%.
  • aminoplastic resins or polyurethanes are used as binders in the top layer.
  • aminoplasts are advantageous.
  • a practical binder is melamine resin.
  • melamine resins and urea resins phenolic resins or mixtures thereof are possible.
  • polyurethanes or prepolymers are also well suited as binders.
  • the mixture can furthermore contain additives, for example effect particles, such as mica, and / or antiabrasive auxiliaries, for example corundum, silicon or porcelain granules, in particular cubic porcelain granules. Also Thickeners may be added as additives. As a thickener cellulose can be used.
  • a further advantageous production of the upper layer provides that the powder mixture is precured before the pressing takes place in the press.
  • a skin formation is generated on the surface of the resting on a functional or stabilizing layer powder mixture.
  • the skin formation can be done by reacting the binder contained in the manner of a fishing or by applying moisture, for example in the form of a water mist and / or by applying heat, for example by IR emitters done.
  • the skin formation fixes the surface as well as color and design.
  • a stirring up of the powder mixture during the pressing process can be avoided.
  • the upper layer can also be constructed in multiple layers. It is possible that the upper layer has an upper layer and a lower layer.
  • the top layer and the bottom layer of the topsheet differ in thickness and / or composition.
  • the upper layer and the lower layer may have different resin contents, dyes or filler degrees, in particular different proportions of wood particles.
  • the upper layer of the upper layer may be transparent even after the compression.
  • At least one functional position is integrated into the upper class.
  • This functional layer is a veneer, in particular a real wood veneer.
  • the functional position can be multi-layered. It is thus possible to provide a plurality of mutually different functional layers.
  • the functional layer can form the basis for the composite material of the upper layer. On the functional position, the powder mixture can be sprinkled. Furthermore, the functional layer can function as a decorative top layer of the cover layer.
  • an advantageous embodiment provides a nonwoven fabric as an additional functional position.
  • the nonwoven fabric consists of wood pulp or pulp.
  • the functional position is carried out in the form of a paper layer or as a flat cellulose fabric or braid.
  • the additional functional layer may in particular be a kraft paper, in particular an impregnated kraft paper.
  • the kraft paper preferably has an impregnation based on melamine, urea or phenolic resin.
  • a functional layer made of non-woven fabric this consists predominantly of pulp fibers, the usual additives such as starch or alum and glue are added.
  • additives, resins and other thermoplastic material components may be contained in the functional layer. It may also consist of the functional layer itself of a thermoplastic material.
  • the combination of different flat functional layers is possible.
  • the functional position can also be multi-layered.
  • Veneer functional layers are made of real wood.
  • two veneer layers are arranged one above the other.
  • the veneer layers are aligned transversely to each other.
  • the veneer sheets have a thickness of 0.3 mm to 0.9 mm.
  • the wood moisture should preferably be less than 14%.
  • a nonwoven functional layer In the case of a nonwoven functional layer, this preferably has a weight per unit area of 80 g / m 2 to 500 g / m 2 .
  • the nonwoven fabric is impregnated with resins.
  • the functional layer of non-woven fabric and / or kraft paper in this embodiment already has resins, which are melted when pressing the top layer with.
  • the functional layer such as veneers, or else an incorporated fleece, is impregnated with the molten powder mixture and impregnated in this process.
  • a resin layer is also formed on the underside of the functional layer.
  • the wood material is a waste product from the production and / or processing of compacted fiberboard.
  • Fiberboard in particular high-density or medium density fiberboard, which are used for example in the production of laminate or parquet flooring, are usually profiled on the edge.
  • the resulting waste products in the form of wood flour come as part of the mixture for the production of the upper layer used.
  • the plate-shaped component may further comprise a stabilizing layer.
  • a stabilizing layer nonwovens, lattice or fabric layers are used, which are incorporated into the plate-shaped component.
  • the stabilization layer is impregnated with aminoplastic binders.
  • the stabilization layer is integrated or embedded in the carrier layer.
  • the stabilization layer can also be arranged under the carrier layer. In this case, the stabilization layer is applied to the underside of the carrier layer.
  • the visible surface of a plate-shaped component according to the invention or the upper layer can be processed.
  • the layer surface is ground, embossed, brushed and / or sealed. Also, a painting of the visible surface is possible.
  • the visible surface may be printed with a decor and / or be provided with a seal.
  • the visible surface of the plate-shaped component preferably has different degrees of gloss.
  • the visible side may have a matt finish in depressions and, in contrast, may have more gloss in elevations.
  • the plate-shaped component has a total thickness of between 3 mm and 10 mm.
  • the total thickness of the device is between 4 mm to 6 mm.
  • the basis weight of the device is greater than or equal to ( ⁇ ) 4.0 kg / m 2 .
  • the basis weight is 5.0 kg / m 2 or higher.
  • layer thicknesses of the top layer are from 0.1 mm to 1.5 mm.
  • the top layer is extremely hard and hard depending on the binder and composition of the binder system resilient or flexible.
  • elastic properties can also be set. This is advantageous in laying, as well as in use.
  • the functional properties in terms of elasticity and flexibility and strength of the carrier layer can be adjusted by the polyol content and by the addition of fillers and additives. This is done by adding to the polyurethane starting material. Furthermore, the appearance or the color of the carrier layer can be adjusted by the addition of dyes.
  • the plate-shaped components are configured rectangular or square.
  • the individual elements are separated from a large format plate in individual planks and profiled on the edge.
  • the practical application of the plate-shaped components is improved in that the side edges of the plate body are provided with locking means.
  • the locking means serve for the mechanical coupling of in a surface covering, in particular a floor covering, adjacent laid components.
  • the locking means are designed in particular in the manner of a click system.
  • a compound of the plate-shaped components via mechanical locking means in particular a lockable tongue and groove profile has the advantage that a surface covering can be installed floating. A bonding of the components to the ground is not necessary.
  • a surface covering of plate-shaped components according to the invention for example a floor covering, can be used immediately after installation.
  • a device according to the invention is waterproof and therefore suitable for wet rooms. Due to the special construction, increased moisture from fresh screeds also does not lead to moisture damage to the component, ie it is not to be expected with swelling or material distortion. It is also advantageous that the component is elastic and flexible and can be cut with a simple cutting device, for example a cutter knife. This has processing or laying technical advantages.
  • the carrier layer also gives the device impression stability and heat-resistant properties.
  • a floor covering of plate-shaped components according to the invention is WegaufNeillbar and reusable. This is advantageous in many fields of application, for example in trade fair or shopfitting for presentation areas and the like.
  • the upper layer and the carrier layer can be manufactured separately from each other and then connected to form a unit. This is preferably done by material bonding, in particular by a surface bonding of the two layers together. This can be done under the influence of pressure and temperature.
  • Another way of producing a component according to the invention provides for the production of the top layer in a first method step.
  • the mixture of fibrous and / or powdered wood material, binder and color pigments is pressed under the influence of temperature and pressure.
  • a functional position can be integrated into the upper layer.
  • the carrier layer is produced and joined to the top layer.
  • the polyurethane material is applied to the back of the top layer. This can be done for example in liquid or gel or pasty form. The needs-based amount of polyurethane material is applied and evened out.
  • the multilayer body of upper layer and applied polyurethane material goes into the curing phase. This takes place under the influence of heat, for example in a heating device.
  • the heater preferably provides for the use of infrared radiators.
  • a stabilizing layer can be integrated into the carrier layer or arranged on the underside of the carrier layer.
  • the stabilization layer can therefore be applied to the still pasty layer of polyurethane material before curing. It is also possible to apply the stabilizing layer after a gelling or hardening of the polyurethane material.
  • the stabilization layer only after completion of the curing of the carrier layer or after passage of the intermediate product by the heater applied. This is expediently carried out immediately after the passage through the heating device, ie before the actual cooling process. In this way, shrinkage, in particular of the carrier layer, can be counteracted. Polyurethane shrinks in the curing phase. A stabilization layer inserted at the right position in the production process can effectively keep the carrier layer flat and counteract the shrinkage.
  • the carrier layer is provided on top and bottom with an impregnated, thermosetting stabilizing layer.
  • the carrier layer is pressed on the upper side with the upper layer and on the underside with a counter-pull in a press under heat and pressure.
  • the carrier layer is heat-resistant and withstands temperatures up to 200 ° C, in particular up to 160 ° C, for 30 seconds non-destructive stood.
  • the bonding of backing layer and top layer can be done in a short-cycle press or a continuous press.
  • the carrier layer is not destroyed by the acting pressing temperature and the pressing pressure.
  • the support layer should be plasticized to a maximum, so that after cooling no influence on the strength is given, therefore, the compression should have no strength-reducing effect in the support layer.
  • the carrier layer is sufficiently thermally stable formulated. This is done by adjusting the polyurethane components and the fillers.
  • the pressing pressure is greater than or equal to 25 kg / cm 2 .
  • the pressing temperatures are greater than 100 ° C and less than 200 ° C.
  • the pressing times are based on the temperature of the top side press plate. That is, the upper press plate has a temperature of greater than 100 ° C in the specified temperature window.
  • the pressing times are 10 seconds and 120 seconds, in particular between 15 seconds and 55 seconds.
  • the pressing temperature at the lower press plate may be lower than the temperature of the upper press plate.
  • Possible and expedient is a temperature difference between the upper press plate and the lower press plate of up to 100 ° C.
  • the temperature of the lower press plate is 25 ° C and above.
  • the temperature of the lower press plate during the pressing process is greater than 60 ° C.
  • top layer is applied as a powder mixture. Covering in compression by a continuous resin film such as an impregnated overlay film is not required. As a result, condensate moisture arising during pressing can escape more easily. Accordingly, adhesion of the top layer to the carrier layer takes place.
  • product-specific composition of the top layer takes place as a powder mixture of fibrous and / or pulverulent wood material, binders and resins and fillers.
  • the support layer based on polyurethane and the top layer of the powder mixture are prepared separately from each other.
  • the top layer is glued or laminated onto the carrier layer and optionally a counter-pull under the carrier layer.
  • a decorative layer is produced / pressed in a first operation.
  • the liquid polyurethane mixture is applied and cured.
  • a stabilization layer is integrated as a countermove.
  • a backing layer of polyurethane is produced in a first operation.
  • the powder mixture is applied and in a press under Temperature effect and pressure pressed together. That is, in one operation, the top layer is made and simultaneously connected to the carrier plate.
  • the PUR support layer contains top and bottom functional layers that allow a compression and secure connection in a press with heat and pressure between the top layer and the carrier layer.

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

Description

Die Erfindung betrifft ein plattenförmiges Bauelement, insbesondere ein Fußbodenpaneel.The invention relates to a plate-shaped component, in particular a floor panel.

Oberflächenbeläge, insbesondere in Form von Bodenbelägen gibt es in vielfältigsten Ausführungsformen. Weit verbreitet sind plattenförmige Bauelemente, insbesondere Fußbodenpaneele in Form von Laminat oder Parkett, mit Trägerplatten aus verdichteten Faserstoffen. Elastische Bodenbeläge sind in Form von PVC-Belägen, Linoleumbelägen oder auch als Korkbeläge bekannt.Surface coverings, especially in the form of floor coverings, are available in a wide variety of embodiments. Widely used are plate-shaped components, in particular floor panels in the form of laminate or parquet, with carrier plates of compacted fibers. Resilient floor coverings are known in the form of PVC coverings, linoleum coverings or as cork coverings.

Fußboden-, Wand- oder Deckenpaneele sowie ähnliche Flächengebilde oder Formkörper sind im Stand der Technik unter anderem durch die DE 10 2013 113 478 A1 , die DE 10 2009 000 717 A1 , die EP 2 523 804 B1 , die DE 10 2005 061 222 A1 oder auch die DE 30 05 707 A1 bekannt.Floor, wall or ceiling panels and similar fabrics or moldings are known in the art, inter alia by the DE 10 2013 113 478 A1 , the DE 10 2009 000 717 A1 , the EP 2 523 804 B1 , the DE 10 2005 061 222 A1 or even the DE 30 05 707 A1 known.

Die DE 10 2013 113 478 A1 offenbart ein Paneel, welches eine Trägerplatte und eine oberseitige Nutzschicht aufweist. Die Trägerplatte besteht aus einem Verbundwerkstoff aus Fasern und einem hydraulischen Bindemittel. Die Nutzschicht besteht aus einem naturwerkstoffverstärktem Kunststoff. Die Trägerplatte und die Nutzschicht sind miteinander heiß verpresst.The DE 10 2013 113 478 A1 discloses a panel having a support plate and a top-side wear layer. The carrier plate consists of a composite material of fibers and a hydraulic binder. The wear layer consists of a natural material-reinforced plastic. The carrier plate and the wear layer are hot-pressed together.

Aus der DE 10 2009 000 717 A1 geht ein Natur/Kunststoff-Flächengebilde hervor, enthaltend Linoxin und Naturharz sowie organische und/oder anorganische Füllstoffe, welche auf ein Trägergewebe aufgetragen sein können.From the DE 10 2009 000 717 A1 is a nature / plastic sheet forth, containing linoxin and natural resin and organic and / or inorganic fillers, which may be applied to a carrier fabric.

Durch die EP 2 523 804 B1 zählt ein Verfahren zum Herstellen einer verschleißbeständigen Oberschicht zum Stand der Technik. Hierzu wird eine Trockenpulverschicht aus einer Mischung von aufgeschlossenen Fasern, einem Bindemittel, Pigmenten und verschleißbeständigen Partikeln auf einen Träger aufgetragen und anschließend die Mischung zu einer blass gefärbten, verschleißbeständigen Schicht ausgehärtet und zwar unter Anwendung von Wärme und Druck.By the EP 2 523 804 B1 includes a method of making a wear resistant topsheet of the prior art. For this purpose, a dry powder layer of a mixture of digested fibers, a binder, pigments and wear-resistant particles is applied to a support and then the mixture is cured to a pale-colored, wear-resistant layer using heat and pressure.

Im Umfang der DE 10 2005 061 222 A1 wird ein Formkörper beschrieben, der pflanzliche Fasern enthält.In the scope of DE 10 2005 061 222 A1 For example, a molded article containing vegetable fibers is described.

Ferner beschreibt die DE 30 05 707 A1 eine großformatige Bauplatte aus im Verbund stehenden Lagen mit unterschiedlicher Dicke und unterschiedlichem Bindemittelanteil sowie ein Verfahren zu deren Herstellung.Furthermore, the describes DE 30 05 707 A1 a large-format building board made of composite layers with different thickness and different binder content and a method for their preparation.

Weiterhin zählt durch die EP 2 755 818 B1 ein Bodenbelag zum Stand der Technik. Dieser weist eine Dekorschicht auf, die aus einem Zellstoffpapier besteht, das mit Polyurethan imprägniert ist. Auf der Dekorschicht ist eine Nutzschicht vorgesehen. Der Bodenbelag weist weiterhin einen Kern und eine Rückenschicht auf. Dekorschicht, Kern und Rückenschicht bestehen jeweils aus Polyurethan.Furthermore counts by the EP 2 755 818 B1 a floor covering the state of the art. This has a decorative layer, which consists of a pulp paper, which is impregnated with polyurethane. On the decorative layer, a wear layer is provided. The flooring also has a core and a backing layer. The decorative layer, core and back layer are each made of polyurethane.

Die DE 1 715 436 U offenbart ein Bauelement für einen Fußbodenbelag. Das Bauelement besteht aus einer Verbundplatte aus einer Deckschicht, die mit einer Isolierschicht verbunden ist. Die Deckschicht kann hart oder elastisch ausgebildet sein und beispielsweise aus Natur- oder Kunststein, ebenso wie aus Holz bestehen.The DE 1 715 436 U discloses a structural element for a floor covering. The device consists of a composite plate of a cover layer, which is connected to an insulating layer. The cover layer may be hard or elastic and, for example, made of natural or artificial stone, as well as made of wood.

Die Isolierschicht soll hart und druckfest sein und beispielsweise aus Stein oder Glaswolle oder Kunststoff bestehen. Gegebenenfalls sind die Deckschicht und die Isolierschicht über eine Tabellisierungslage verbunden.The insulating layer should be hard and pressure-resistant and consist for example of stone or glass wool or plastic. Optionally, the cover layer and the insulating layer are connected via a tabulation layer.

Auch die DE 296 20 751 U1 erläutert eine Verbundplatte mit mindestens zwei Schichten, nämlich einer Trägerschicht aus Natur- und Kunststoffmaterialien und einer Deckschicht aus nativen und/oder synthetischen Fasern.Also the DE 296 20 751 U1 illustrates a composite panel having at least two layers, namely a backing layer of natural and plastic materials and a cover layer of native and / or synthetic fibers.

Im Rahmen der DE 10 2004 003 457 A1 wird eine Fliese offenbart, die im Wesentlichen aus einem Pflanzenmaterial besteht, die mit einem duroplastischen Bindemittel versetzt sind.As part of the DE 10 2004 003 457 A1 discloses a tile, which consists essentially of a plant material, which are mixed with a thermosetting binder.

Gegenstand der DE 199 44 399 A1 ist ein Fußbodenelement mit einer Trägerschicht und wenigstens einer einseitig auf diese angeordneten und fest mit ihr verbundenen Deckschicht. Die Trägerschicht ist aus Polyurethan oder Acrylat als Bindemittel und darin angeordneten Füllstoffen gebildet.Subject of the DE 199 44 399 A1 is a floor element with a carrier layer and at least one on one side arranged on this and firmly connected to it cover layer. The carrier layer is formed of polyurethane or acrylate as a binder and fillers disposed therein.

Elastische Bodenbeläge sind zudem in der EP 2 907 655 A1 sowie der EP 1 938 963 B2 beschrieben.Elastic floor coverings are also in the EP 2 907 655 A1 as well as the EP 1 938 963 B2 described.

Ein gattungsgemäßes plattenförmiges Bauelement ist ferner aus der EP 2 777 928 A1 bekannt.A generic plate-shaped component is further from the EP 2 777 928 A1 known.

Der Erfindung liegt die Aufgabe zugrunde, ein herstellungs- und anwendungstechnisch verbessertes plattenförmiges Bauelement mit sehr guten Verlege- und Gebrauchseigenschaften, insbesondere ein Fußbodenpaneel, aufzuzeigen.The invention has for its object to provide a manufacturing and application technology improved plate-shaped component with very good installation and use properties, especially a floor panel show.

Die Lösung dieser Aufgabe zeigt Anspruch 1 auf.The solution to this problem is claimed in claim 1.

Vorteilhafte Ausgestaltungen des erfindungsgemäßen Grundgedankens sind Gegenstand der abhängigen Ansprüche.Advantageous embodiments of the inventive concept are the subject of the dependent claims.

Danach ist vorgesehen, dass das plattenförmige Bauelement eine Oberschicht und eine Trägerschicht aufweist. Diese sind zu einer Einheit verbunden. Die Oberschicht besteht aus einer Mischung aus faser- und/oder pulverförmigem Holzwerkstoff, Bindemitteln und Farbpigmenten, welche unter Temperatur- und Druckeinwirkung verpresst ist.Thereafter, it is provided that the plate-shaped component has an upper layer and a carrier layer. These are connected in one unit. The upper layer consists of a mixture of fibrous and / or powdered wood material, binders and color pigments, which is pressed under the effect of temperature and pressure.

Diese Oberschicht zeichnet sich durch besondere Eigenschaften aus: Sie ist hoch abriebfest, vergleichbar mit Laminatböden, im Gegensatz zu derartigen Belägen aber im Grundaufbau homogener und in größeren Schichtdicken realisierbar. Zudem sehr kratzbeständig und belastbar wie Fliesen oder Natursteinbeläge, allerdings deutlich haptisch angenehmer und beim Körperkontakt /Barfussgehen deutlich wärmer als Fliesenbeläge.This top layer is characterized by special properties: it is highly resistant to abrasion, comparable to laminate flooring, but in contrast to such coverings, it can be made more homogeneous in its basic structure and in larger layer thicknesses. In addition, very scratch-resistant and durable like tiles or natural stone coverings, but clearly haptically more pleasant and with body contact / barefoot walking much warmer than tile coverings.

Die Trägerschicht ist auf Basis von Polyurethan gebildet. Die Trägerschicht besteht folglich aus Polyurethanbindemitteln (ein- oder zweikomponentig) und Füllstoffen bzw. besteht zum überwiegenden Teil aus polyurethanbasierenden Bindemitteln und Füllstoffen. Ein Aspekt sieht hierbei die Verwendung von zwei Komponenten eines Polyurethans vor sowie Füllstoffe wie Kreide, Talkum, mineralische Füllstoffe, auch gegebenenfalls Zellulose als Füllstoffe, Pigmente und Schaumbildner bzw. Porenbildner. Ebenfalls sind Additive und Stabilisierungsmittel, vorgesehen.The carrier layer is formed on the basis of polyurethane. The carrier layer thus consists of polyurethane binders (one- or two-component) and fillers or consists for the most part of polyurethane-based binders and fillers. One aspect in this case is the use of two components of a polyurethane and also fillers such as chalk, talc, mineral fillers, optionally also cellulose as fillers, pigments and foaming agents or pore formers. Also provided are additives and stabilizers.

Die Polyurethankomponenten bzw. Polyurethanbindemittel können auch zumindest teilweise aus Recyclingprodukten, also recyceltem Polyurethan bestehen und zwar in Faserform oder kubischer Form, z. B. als aus Polyurethan-Schäumen oder -Frässpänen. Besonders sinnvoll sind Polyurethankomponenten, die aus nachwachsenden Rohstoffen bestehen, wie Polyole aus diversen pflanzlichen Ölen.The polyurethane components or polyurethane binders may also at least partially made of recycled products, ie recycled polyurethane and in fiber or cubic form, z. B. as polyurethane foams or fraying chips. Particularly useful are polyurethane components, which consist of renewable raw materials, such as polyols from various vegetable oils.

Das Polyurethan der Trägerschicht kann aus einem aromatischen Polyol synthetisiert werden. Hierbei handelt es sich um biogene Polyole, welche aus nachwachsenden Rohstoffen gewonnen werden. Möglich ist es auch, dass Polyurethan aus einem aliphatischen Polyol herzustellen.The polyurethane of the carrier layer can be synthesized from an aromatic polyol. These are biogenic polyols, which are obtained from renewable raw materials. It is also possible to produce the polyurethane from an aliphatic polyol.

Die Trägerschicht kann ferner neben Polyurethan Füllstoffe, Additive und/oder Farbstoffe enthalten. Diese sind in den die Trägerschicht bildenden Ausgangswerkstoff eingemischt. Über die Füllstoffe und/oder Additive können die Sichteigenschaften, insbesondere deren Elastizität und die Festigkeit eingestellt werden. Farbstoffe dienen zur Farbgebung der Trägerschicht.The carrier layer may also contain, in addition to polyurethane fillers, additives and / or dyes. These are mixed into the carrier material forming the base layer. About the fillers and / or additives the visual properties, in particular their elasticity and strength can be adjusted. Dyes are used to color the backing layer.

Die Oberschicht und die Trägerschicht können zunächst separat gefertigt und anschließend miteinander verklebt sein.The top layer and the carrier layer can initially be manufactured separately and then glued together.

Die Oberschicht und die Trägerschicht können miteinander verpresst sein. Ein Aspekt der Erfindung sieht das verpressen von Oberschicht und Trägerschicht in einer Kurztaktpresse vor.The top layer and the carrier layer can be pressed together. One aspect of the invention provides for the compression of the top layer and carrier layer in a short-cycle press.

Ein wesentlicher Aspekt der Erfindung ist die Oberschicht, die aus einer Mischung aus faser- und/oder pulverförmigem Holzwerkstoff, Bindemitteln und Farbpigmenten gebildet ist. Diese Mischung wird unter Temperatureinfluss und Druckeinwirkung verpresst. Der Pressvorgang erfolgt zwischen einem unteren Pressblech und einem oberen Pressblech in einer beheizten Presse. Die verpresste Mischung kann alleine die Oberschicht bilden.An essential aspect of the invention is the upper layer, which is formed from a mixture of fibrous and / or pulverulent wood material, binders and color pigments. This mixture is pressed under the influence of temperature and pressure. The pressing process takes place between a lower press plate and an upper press plate in a heated press. The pressed mixture alone can form the upper layer.

Bei der Oberschicht handelt es sich um einen duroplastisch verarbeiteten Verbundwerkstoff, der aus unterschiedlichen Anteilen von faser- und/oder pulverförmigem Holzwerkstoff und Bindemittel in Form von Kunststoffen und Additiven bzw. Farbpigmenten gebildet ist. Auch thermoplastische Rohstoffe oder thermoplastische Komponenten können in den Fertigungsprozess miteinfließen und in der ausgehärteten Oberschicht eingebettet /aufgeschmolzen sein. Die Mischung aus faser- und/oder pulverförmigem Holzwerkstoff, Bindemitteln und Farbpigmenten wird im Rahmen der Erfindung auch als Pudergemisch bezeichnet. Im Pudergemisch enthaltene Holzfasern weisen eine Länge von bis zu 500 µm auf.The upper layer is a thermoset processed composite material which is formed from different proportions of fibrous and / or pulverulent wood material and binder in the form of plastics and additives or color pigments. Also thermoplastic raw materials or thermoplastic components may be included in the manufacturing process and embedded / melted in the cured top layer. The mixture of fibrous and / or pulverulent wood material, binders and color pigments is also referred to as a powder mixture in the context of the invention. Wood fibers contained in the powder mixture have a length of up to 500 μm.

Der Anteil an Holzwerkstoff in der Mischung beträgt mindestens 30 %. Insbesondere liegt der Anteil an Holzwerkstoff und oder holzbasierenden Recyclaten in der Mischung über 30 %.The proportion of wood material in the mixture is at least 30%. In particular, the proportion of wood material and or wood-based recyclates in the mixture is over 30%.

Im Rahmen der Erfindung kommen als Bindemittel in der Oberschicht insbesondere aminoplastische Harze oder Polyurethane zur Anwendung. Insbesondere sind Aminoplaste vorteilhaft. Ein für die Praxis vorteilhaftes Bindemittel ist Melaminharz. Darüber hinaus sind neben Melaminharzen auch Harnstoffharze, Phenolharze oder Gemische derselben möglich. Weiterhin sind Polyurethane oder Prepolymere auch als Bindemittel gut geeignet.In the context of the invention, in particular aminoplastic resins or polyurethanes are used as binders in the top layer. In particular, aminoplasts are advantageous. A practical binder is melamine resin. In addition, besides melamine resins and urea resins, phenolic resins or mixtures thereof are possible. Furthermore, polyurethanes or prepolymers are also well suited as binders.

Die Mischung kann weiterhin Additive, beispielsweise Effektpartikel wie Glimmer, und/oder antiabrasive Hilfsstoffe, beispielsweise Korund, Silicium oder Porzellankörnungen, insbesondere kubische Porzellankörnungen, enthalten. Auch Verdickungsmittel können als Additive zugefügt sein. Als Verdickungsmittel kann Zellulose eingesetzt werden.The mixture can furthermore contain additives, for example effect particles, such as mica, and / or antiabrasive auxiliaries, for example corundum, silicon or porcelain granules, in particular cubic porcelain granules. Also Thickeners may be added as additives. As a thickener cellulose can be used.

Eine weitere vorteilhafte Fertigung der Oberschicht sieht vor, dass das Pudergemisch vorgehärtet wird bevor die Verpressung in der Presse erfolgt. Hierbei wird auf der Oberfläche des auf einer Funktions- oder Stabilisierungslage aufliegenden Pudergemisches eine Hautbildung erzeugt. Die Hautbildung kann durch Reaktionsstart der enthaltenen Bindemittel nach Art eines Angelierens geschehen oder durch Aufbringung von Feuchtigkeit, beispielsweise in Form eines Wassernebels und/oder auch durch Wärmebeaufschlagung, beispielsweise durch IR-Strahler, erfolgen. Die Hautbildung fixiert die Oberfläche sowie Farbe und Design. Weiterhin kann ein Aufwirbeln des Pudergemisches beim Pressvorgang vermieden werden.A further advantageous production of the upper layer provides that the powder mixture is precured before the pressing takes place in the press. Here, a skin formation is generated on the surface of the resting on a functional or stabilizing layer powder mixture. The skin formation can be done by reacting the binder contained in the manner of a fishing or by applying moisture, for example in the form of a water mist and / or by applying heat, for example by IR emitters done. The skin formation fixes the surface as well as color and design. Furthermore, a stirring up of the powder mixture during the pressing process can be avoided.

Die Oberschicht kann auch mehrlagig aufgebaut sein. Hierbei ist es möglich, dass die Oberschicht eine obere Lage und eine untere Lage aufweist. Die obere Lage und die untere Lage der Oberschicht differieren voneinander in Dicke und/oder in der Zusammensetzung. Die obere Lage und die untere Lage können unterschiedliche Harzanteile, Farbstoffe oder Füllstoffgrade, insbesondere unterschiedliche Anteile von Holzpartikeln, aufweisen.The upper layer can also be constructed in multiple layers. It is possible that the upper layer has an upper layer and a lower layer. The top layer and the bottom layer of the topsheet differ in thickness and / or composition. The upper layer and the lower layer may have different resin contents, dyes or filler degrees, in particular different proportions of wood particles.

In einer besonders vorteilhaften Ausführungsform kann die obere Lage der Oberschicht auch nach der Verpressung transparent sein.In a particularly advantageous embodiment, the upper layer of the upper layer may be transparent even after the compression.

In die Oberschicht ist zumindest eine Funktionslage integriert. Bei dieser Funktionslage handelt es sich um ein Furnier, insbesondere ein Echtholzfurnier.At least one functional position is integrated into the upper class. This functional layer is a veneer, in particular a real wood veneer.

Die Funktionslage kann mehrlagig aufgebaut sein. Es können also mehrere auch voneinander verschiedene Funktionslagen vorgesehen sein.The functional position can be multi-layered. It is thus possible to provide a plurality of mutually different functional layers.

Als zusätzliche Funktionslage kann des Weiteren ein Vlies oder eine Gewebelage eingesetzt werden. Die Funktionslage kann die Grundlage für den Verbundwerkstoff der Oberschicht bilden. Auf die Funktionslage kann das Pudergemisch aufgestreut werden. Ferner kann die Funktionslage als dekorgebende obere Lage der Deckschicht fungieren.As an additional functional layer, it is also possible to use a fleece or a fabric layer. The functional layer can form the basis for the composite material of the upper layer. On the functional position, the powder mixture can be sprinkled. Furthermore, the functional layer can function as a decorative top layer of the cover layer.

Eine vorteilhafte Ausführungsform sieht ein Faservlies als zusätzliche Funktionslage vor. Besonders vorteilhaft besteht das Faservlies aus Zellstoff oder aus Holzstoff. Insbesondere wird die Funktionslage in Form einer Papierlage oder als flächiges Zellulosegewebe bzw. -geflecht ausgeführt. Die zusätzliche Funktionslage kann insbesondere ein Kraftpapier sein, insbesondere ein imprägniertes Kraftpapier. Vorzugsweise weist das Kraftpapier eine Imprägnierung auf Basis von Melamin, Harnstoff oder Phenolharz auf. Bei einer Funktionslage aus Faservlies besteht diese zum überwiegenden Teil aus Zellstofffasern, dem übliche Zusätze wie Stärke oder Alaun und Leim zugesetzt sind. Weiterhin können Additive, Harze und weitere thermoplastische Materialkomponenten in der Funktionslage enthalten sein. Es kann auch die Funktionslage selbst aus einem thermoplastischen Werkstoff bestehen.An advantageous embodiment provides a nonwoven fabric as an additional functional position. Particularly advantageously, the nonwoven fabric consists of wood pulp or pulp. In particular, the functional position is carried out in the form of a paper layer or as a flat cellulose fabric or braid. The additional functional layer may in particular be a kraft paper, in particular an impregnated kraft paper. The kraft paper preferably has an impregnation based on melamine, urea or phenolic resin. In a functional layer made of non-woven fabric, this consists predominantly of pulp fibers, the usual additives such as starch or alum and glue are added. Furthermore, additives, resins and other thermoplastic material components may be contained in the functional layer. It may also consist of the functional layer itself of a thermoplastic material.

Auch die Kombination von unterschiedlichen flächigen Funktionslagen ist möglich. Die Funktionslage kann auch mehrlagig aufgebaut sein.The combination of different flat functional layers is possible. The functional position can also be multi-layered.

Furnier-Funktionslagen bestehen aus Echtholz. In besonderen Fällen werden zwei Furnierlagen übereinander angeordnet. Vorzugsweise werden die Furnierlagen quer zueinander ausgerichtet. Die Furnierlagen haben eine Stärke von 0,3 mm bis 0,9 mm. Die Holzfeuchte sollte vorzugsweise kleiner als 14 % sein.Veneer functional layers are made of real wood. In special cases, two veneer layers are arranged one above the other. Preferably, the veneer layers are aligned transversely to each other. The veneer sheets have a thickness of 0.3 mm to 0.9 mm. The wood moisture should preferably be less than 14%.

Bei einer Funktionslage aus Faservlies weist diese vorzugsweise ein Flächengewicht von 80 g/m2 bis 500 g/m2 auf. Besonders vorteilhaft ist das Faservlies mit Harzen imprägniert. Die Funktionslage aus Faservlies und/oder Kraftpapier weist in dieser Ausführung bereits Harze auf, die beim Verpressen der Oberschicht mit aufgeschmolzen werden. Beim Pressvorgang werden die Funktionslage, wie Furniere, oder auch ein eingegliedertes Vlies vom aufgeschmolzenen Pudergemisch durchtränkt und hierbei imprägniert. In der Folge bildet sich auch unterseitig der Funktionslage eine Harzschicht aus.In the case of a nonwoven functional layer, this preferably has a weight per unit area of 80 g / m 2 to 500 g / m 2 . Particularly advantageously, the nonwoven fabric is impregnated with resins. The functional layer of non-woven fabric and / or kraft paper in this embodiment already has resins, which are melted when pressing the top layer with. During the pressing process, the functional layer, such as veneers, or else an incorporated fleece, is impregnated with the molten powder mixture and impregnated in this process. As a result, a resin layer is also formed on the underside of the functional layer.

Ein ökologischer und auch wirtschaftlich vorteilhafter Aspekt sieht vor, dass der Holzwerkstoff ein Abprodukt aus der Herstellung und/oder Bearbeitung von verdichteten Faserplatten ist. Faserplatten, insbesondere hochverdichtete oder mitteldichtverdichtete Faserplatten, die beispielsweise bei der Herstellung von Laminat- oder Parkettbodenbelägen verwendet werden, werden in aller Regel randseitig profiliert. Die hierbei anfallenden Abprodukte in Form von Holzmehl kommen als Bestandteil der Mischung für die Herstellung der Oberschicht zur Anwendung.An ecological and economically advantageous aspect provides that the wood material is a waste product from the production and / or processing of compacted fiberboard. Fiberboard, in particular high-density or medium density fiberboard, which are used for example in the production of laminate or parquet flooring, are usually profiled on the edge. The resulting waste products in the form of wood flour come as part of the mixture for the production of the upper layer used.

Das plattenförmige Bauelement kann ferner eine Stabilisierungslage aufweisen. Insbesondere kommen als Stabilisierungslage Vliese, Gitter- oder Gewebelagen zur Anwendung, die in das plattenförmige Bauelement eingegliedert sind. Vorzugsweise ist die Stabilisierungslage mit aminoplastischen Bindemitteln imprägniert. Besonders vorteilhaft ist die Stabilisierungslage in die Trägerschicht integriert bzw. eingebettet. Die Stabilisierungslage kann auch unter der Trägerschicht angeordnet sein. In diesem Fall ist die Stabilisierungslage auf der Unterseite der Trägerschicht aufgebracht.The plate-shaped component may further comprise a stabilizing layer. In particular, as stabilization layer, nonwovens, lattice or fabric layers are used, which are incorporated into the plate-shaped component. Preferably, the stabilization layer is impregnated with aminoplastic binders. Particularly advantageously, the stabilization layer is integrated or embedded in the carrier layer. The stabilization layer can also be arranged under the carrier layer. In this case, the stabilization layer is applied to the underside of the carrier layer.

Die Sichtfläche eines erfindungsgemäßen plattenförmigen Bauelements bzw. der Oberschicht kann bearbeitet sein. Insbesondere ist die Schichtfläche geschliffen, geprägt, gebürstet und/oder versiegelt. Auch eine Lackierung der Sichtfläche ist möglich.The visible surface of a plate-shaped component according to the invention or the upper layer can be processed. In particular, the layer surface is ground, embossed, brushed and / or sealed. Also, a painting of the visible surface is possible.

Weiterhin kann die Sichtfläche mit einem Dekor bedruckt sein und/oder mit einer Versiegelung versehen sein.Furthermore, the visible surface may be printed with a decor and / or be provided with a seal.

Vorzugsweise weist die Sichtfläche des plattenförmigen Bauelements unterschiedliche Glanzgrade auf. Hierbei können dekorabhängig bis zu vier unterschiedliche Glanzgrade vorgesehen sein, beispielsweise kann die Sichtseite in Vertiefungen matt und demgegenüber in Erhöhungen mehr Glanz aufweisen.The visible surface of the plate-shaped component preferably has different degrees of gloss. Depending on the decor, up to four different degrees of gloss can be provided, for example, the visible side may have a matt finish in depressions and, in contrast, may have more gloss in elevations.

Das plattenförmige Bauelement weist eine Gesamtstärke zwischen 3 mm und 10 mm auf. Insbesondere liegt die Gesamtstärke des Bauelements zwischen 4 mm bis 6 mm.The plate-shaped component has a total thickness of between 3 mm and 10 mm. In particular, the total thickness of the device is between 4 mm to 6 mm.

Das Flächengewicht des Bauelements ist größer oder gleich (≥) 4,0 kg/m2. Insbesondere ist das Flächengewicht 5,0 kg/m2 oder höher.The basis weight of the device is greater than or equal to (≥) 4.0 kg / m 2 . In particular, the basis weight is 5.0 kg / m 2 or higher.

Bei Auftragsmengen des Pudergemischs von 100 g/m2 bis 2.000 g/m2 ergeben sich Schichtdicken der Oberschicht von 0,1 mm bis 1,5 mm. Die Oberschicht ist je nach Bindemittel und Zusammensetzung des Bindemittelsystems extrem hart und belastbar oder auch biegsam. Vorteilhaft können auch elastische Eigenschaften eingestellt werden. Dies ist bei der Verlegung vorteilhaft, ebenso wie beim Gebrauch.For application quantities of the powder mixture from 100 g / m 2 to 2,000 g / m 2 , layer thicknesses of the top layer are from 0.1 mm to 1.5 mm. The top layer is extremely hard and hard depending on the binder and composition of the binder system resilient or flexible. Advantageously, elastic properties can also be set. This is advantageous in laying, as well as in use.

Die Funktionseigenschaften hinsichtlich Elastizität und Biegsamkeit sowie Festigkeit der Trägerschicht können durch den Polyolgehalt sowie durch die Zugabe von Füllstoffen und Additiven eingestellt werden. Dies erfolgt durch die Zugabe zum Polyurethanausgangswerkstoff. Weiterhin kann das Aussehen bzw. die Farbe der Trägerschicht durch die Zugabe von Farbstoffen eingestellt werden.The functional properties in terms of elasticity and flexibility and strength of the carrier layer can be adjusted by the polyol content and by the addition of fillers and additives. This is done by adding to the polyurethane starting material. Furthermore, the appearance or the color of the carrier layer can be adjusted by the addition of dyes.

Vorzugsweise sind die plattenförmigen Bauelemente rechteckig oder quadratisch konfiguriert. Dazu werden die einzelnen Elemente aus einer Großformatplatte in Einzeldielen aufgetrennt und randseitig profiliert. Die praktische Anwendung der plattenförmigen Bauelemente wird dadurch verbessert, dass die Seitenränder der Plattenkörper mit Verriegelungsmitteln versehen sind. Die Verriegelungsmittel dienen zur mechanischen Koppelung von in einem Oberflächenbelag, insbesondere einem Fußbodenbelag, benachbart verlegten Bauelementen. Die Verriegelungsmittel sind insbesondere nach Art eines Klick-Systems gestaltet.Preferably, the plate-shaped components are configured rectangular or square. For this purpose, the individual elements are separated from a large format plate in individual planks and profiled on the edge. The practical application of the plate-shaped components is improved in that the side edges of the plate body are provided with locking means. The locking means serve for the mechanical coupling of in a surface covering, in particular a floor covering, adjacent laid components. The locking means are designed in particular in the manner of a click system.

Eine Verbindung der plattenförmigen Bauelemente über mechanische Verriegelungsmittel, insbesondere einem verriegelbaren Nut-Feder-Profil hat den Vorteil, dass ein Flächenbelag schwimmend verlegt werden kann. Eine Verklebung der Bauelemente mit dem Untergrund ist nicht notwendig. Ein Flächenbelag aus erfindungsgemäßen plattenförmigen Bauelementen, beispielsweise ein Bodenbelag, ist nach dem Verlegen sofort nutzbar.A compound of the plate-shaped components via mechanical locking means, in particular a lockable tongue and groove profile has the advantage that a surface covering can be installed floating. A bonding of the components to the ground is not necessary. A surface covering of plate-shaped components according to the invention, for example a floor covering, can be used immediately after installation.

Ein erfindungsgemäßes Bauelement ist wasserfest und damit feuchtraumgeeignet. Aufgrund der besonderen Aufbaukonstruktion führt erhöhte Feuchtigkeit aus frischen Estrichen auch nicht zu Feuchtigkeitsschäden an dem Bauelement, d.h. es ist nicht mit Quellschäden oder Materialverzug zu rechnen. Weiterhin vorteilhaft ist, dass das Bauelement elastisch und biegsam ist sowie mit einer einfachen Schneideinrichtung, beispielsweise einem Cuttermesser, schneidbar ist. Dies hat verarbeitungs- bzw. verlegungstechnische Vorteile. Die Trägerschicht verleiht dem Bauelement zudem Eindruckstabilität und hitzebeständige Eigenschaften.A device according to the invention is waterproof and therefore suitable for wet rooms. Due to the special construction, increased moisture from fresh screeds also does not lead to moisture damage to the component, ie it is not to be expected with swelling or material distortion. It is also advantageous that the component is elastic and flexible and can be cut with a simple cutting device, for example a cutter knife. This has processing or laying technical advantages. The carrier layer also gives the device impression stability and heat-resistant properties.

Ein Bodenbelag aus erfindungsgemäßen plattenförmigen Bauelementen ist wiederaufnehmbar und wiederverwendbar. Dies ist in vielen Einsatzbereichen vorteilhaft, beispielsweise im Messe- oder Ladenbau für Präsentationsflächen und Ähnliches.A floor covering of plate-shaped components according to the invention is wiederaufnehmbar and reusable. This is advantageous in many fields of application, for example in trade fair or shopfitting for presentation areas and the like.

Zur Herstellung eines erfindungsgemäßen plattenförmigen Bauelements können die Oberschicht und die Trägerschicht separat voneinander gefertigt und anschließend zu einer Einheit verbunden werden. Dies erfolgt vorzugsweise stoffschlüssig, insbesondere durch ein flächiges Verkleben der beiden Schichten miteinander. Dies kann unter Einwirkung von Druck und Temperatur erfolgen.To produce a plate-shaped component according to the invention, the upper layer and the carrier layer can be manufactured separately from each other and then connected to form a unit. This is preferably done by material bonding, in particular by a surface bonding of the two layers together. This can be done under the influence of pressure and temperature.

Eine andere Art der Herstellung eines erfindungsgemäßen Bauelements sieht die Herstellung der Oberschicht in einem ersten Verfahrensschritt vor. Hierbei wird die Mischung aus faser- und/oder pulverförmigem Holzwerkstoff, Bindemittel und Farbpigmenten unter Temperatureinfluss und Druckeinwirkung verpresst. Gegebenenfalls kann in die Oberschicht eine Funktionslage integriert sein.Another way of producing a component according to the invention provides for the production of the top layer in a first method step. Here, the mixture of fibrous and / or powdered wood material, binder and color pigments is pressed under the influence of temperature and pressure. Optionally, a functional position can be integrated into the upper layer.

In einem weiteren Verfahrensschritt wird die Trägerschicht hergestellt und mit der Oberschicht verbunden. Hierzu wird der Polyurethanwerkstoff auf die Rückseite der Oberschicht aufgetragen. Dies kann beispielsweise in flüssiger bzw. gelförmiger oder pastöser Form erfolgen. Die bedarfsgerechte Menge an Polyurethanwerkstoff wird aufgetragen und vergleichmäßigt. Anschließend geht der Mehrlagenkörper aus Oberschicht und aufgetragenem Polyurethanwerkstoff in die Aushärtephase. Dies erfolgt unter Wärmeeinfluss, beispielsweise in einer Heizeinrichtung. Die Heizeinrichtung sieht vorzugsweise die Verwendung von Infrarotstrahlern vor.In a further method step, the carrier layer is produced and joined to the top layer. For this purpose, the polyurethane material is applied to the back of the top layer. This can be done for example in liquid or gel or pasty form. The needs-based amount of polyurethane material is applied and evened out. Subsequently, the multilayer body of upper layer and applied polyurethane material goes into the curing phase. This takes place under the influence of heat, for example in a heating device. The heater preferably provides for the use of infrared radiators.

Vor der Aushärtung aber auch in Zwischenstufen oder im Anschluss an die Aushärtung kann eine Stabilisierungslage in die Trägerschicht integriert oder unterseitig der Trägerschicht angeordnet werden. Die Stabilisierungsschicht kann folglich vor dem Aushärten auf die noch pastöse Lage aus Polyurethanwerkstoff aufgebracht werden. Möglich ist es auch, die Stabilisierungslage nach einem Angelieren bzw. Anhärten des Polyurethanwerkstoffs aufzubringen. Schließlich ist es auch möglich, die Stabilisierungslage erst nach Abschluss der Aushärtung der Trägerschicht bzw. nach Durchlauf des Zwischenprodukts durch die Heizeinrichtung aufzubringen. Dies erfolgt sinnvollerweise unmittelbar im Anschluss an den Durchlauf durch die Heizeinrichtung, also vor dem eigentlichen Abkühlprozess. Hierdurch kann eine Schrumpfung insbesondere der Trägerschicht entgegengewirkt werden. Polyurethan schrumpft in der Aushärtungsphase. Eine an der richtigen Position im Produktionsprozess eingelegte Stabilisierungslage kann die Trägerlage wirkungsvoll plan halten und dem Schrumpf entgegen wirken.Before curing but also in intermediate stages or after curing, a stabilizing layer can be integrated into the carrier layer or arranged on the underside of the carrier layer. The stabilization layer can therefore be applied to the still pasty layer of polyurethane material before curing. It is also possible to apply the stabilizing layer after a gelling or hardening of the polyurethane material. Finally, it is also possible, the stabilization layer only after completion of the curing of the carrier layer or after passage of the intermediate product by the heater applied. This is expediently carried out immediately after the passage through the heating device, ie before the actual cooling process. In this way, shrinkage, in particular of the carrier layer, can be counteracted. Polyurethane shrinks in the curing phase. A stabilization layer inserted at the right position in the production process can effectively keep the carrier layer flat and counteract the shrinkage.

Alternativ wird die Trägerschicht ober- und unterseitig mit einer imprägnierten, wärmehärtbaren Stabilisierungsschicht versehen. In einem zweiten Arbeitsschritt wird die Trägerschicht oberseitig mit der Oberschicht und unterseitig mit einem Gegenzug in einer Presse unter Hitze und Druck verpresst.Alternatively, the carrier layer is provided on top and bottom with an impregnated, thermosetting stabilizing layer. In a second step, the carrier layer is pressed on the upper side with the upper layer and on the underside with a counter-pull in a press under heat and pressure.

Die Trägerschicht ist hitzeresistent und hält Temperaturen bis 200° C, insbesondere bis 160° C, für 30 Sekunden zerstörungsfrei stand.The carrier layer is heat-resistant and withstands temperatures up to 200 ° C, in particular up to 160 ° C, for 30 seconds non-destructive stood.

Das Verbinden von Trägerschicht und Oberschicht kann in einer Kurztaktpresse oder einer kontinuierlichen Presse erfolgen. Die Trägerschicht wird dabei nicht durch die einwirkende Presstemperatur und dem Pressdruck zerstört. Die Trägerschicht soll maximal plastifiziert werden, so dass nach der Abkühlung keine Beeinflussung der Festigkeit gegeben ist, mithin soll das Verpressen keine festigkeitsmindernde Wirkung in der Trägerschicht haben. Hierzu ist die Trägerschicht ausreichend wärmestabil formuliert. Dies erfolgt durch die Einstellung der Polyurethankomponenten und der Füllstoffe.The bonding of backing layer and top layer can be done in a short-cycle press or a continuous press. The carrier layer is not destroyed by the acting pressing temperature and the pressing pressure. The support layer should be plasticized to a maximum, so that after cooling no influence on the strength is given, therefore, the compression should have no strength-reducing effect in the support layer. For this purpose, the carrier layer is sufficiently thermally stable formulated. This is done by adjusting the polyurethane components and the fillers.

Für das Verpressen sowohl bei der Herstellung der Oberschicht alleine als auch beim Verbinden oder Verpressen von Oberschicht und Trägerschicht zur Herstellung des plattenförmigen Bauelements gelten die nachfolgenden Bedingungen:
Der Pressdruck ist größer oder gleich 25 kg/cm2. Die Presstemperaturen sind größer als 100°C und kleiner als 200°C. Die Presszeiten beziehen sich auf die Temperatur des oberseitigen Pressbleches. Das heißt, das obere Pressblech hat eine Temperatur von größer 100°C in dem angegebenen Temperaturfenster. Die Presszeiten betragen 10 Sekunden und 120 Sekunden, insbesondere zwischen 15 Sekunden und 55 Sekunden.For the compression both in the production of the top layer alone as well as the joining or pressing of the top layer and carrier layer for the production of the plate-shaped component, the following conditions apply:
The pressing pressure is greater than or equal to 25 kg / cm 2 . The pressing temperatures are greater than 100 ° C and less than 200 ° C. The pressing times are based on the temperature of the top side press plate. That is, the upper press plate has a temperature of greater than 100 ° C in the specified temperature window. The pressing times are 10 seconds and 120 seconds, in particular between 15 seconds and 55 seconds.

Die Presstemperatur am unteren Pressblech kann geringer sein als die Temperatur des oberen Pressblechs. Möglich und auch zweckmäßig ist eine Temperaturdifferenz zwischen oberem Pressblech und unterem Pressblech von bis zu 100°C. Die Temperatur des unteren Pressblechs beträgt 25°C und darüber. Vorzugsweise ist die Temperatur des unteren Pressblechs beim Pressvorgang größer als 60°C.The pressing temperature at the lower press plate may be lower than the temperature of the upper press plate. Possible and expedient is a temperature difference between the upper press plate and the lower press plate of up to 100 ° C. The temperature of the lower press plate is 25 ° C and above. Preferably, the temperature of the lower press plate during the pressing process is greater than 60 ° C.

Ein wesentlicher vorteilhafter Aspekt der Erfindung besteht darin, dass die Oberschicht als Pulvermischung appliziert wird. Eine Abdeckung bei der Verpressung durch einen durchgängigen Harzfilm, wie beispielsweise einem imprägnierten Overlayfilm ist nicht erforderlich. Hierdurch kann bei der Verpressung entstehende Kondensationsfeuchte leichter entweichen. Dementsprechend erfolgt eine Haftung der Oberschicht an der Trägerschicht. Wie erwähnt, erfolgt die produktspezifische Zusammensetzung der Oberschicht als Pulvermischung aus faser- und/oder pulverförmigem Holzwerkstoff, Bindemitteln sowie Harzen und Füllstoffen.An essential advantageous aspect of the invention is that the top layer is applied as a powder mixture. Covering in compression by a continuous resin film such as an impregnated overlay film is not required. As a result, condensate moisture arising during pressing can escape more easily. Accordingly, adhesion of the top layer to the carrier layer takes place. As mentioned, the product-specific composition of the top layer takes place as a powder mixture of fibrous and / or pulverulent wood material, binders and resins and fillers.

Nachfolgend sind noch einmal drei Varianten eines Prozesses zur Herstellung eines erfindungsgemäßen plattenförmigen Bauelementes wiedergegeben:Below, three variants of a process for producing a plate-shaped component according to the invention are shown again:

Verfahren 1Method 1

Die Trägerschicht auf Basis von Polyurethan und die Oberschicht aus dem Pudergemisch werden separat voneinander hergestellt. In einem weiteren Arbeitsschritt wird die Oberschicht auf die Trägerschicht und gegebenenfalls ein Gegenzug unter der Trägerschicht aufgeklebt oder aufkaschiert.The support layer based on polyurethane and the top layer of the powder mixture are prepared separately from each other. In a further step, the top layer is glued or laminated onto the carrier layer and optionally a counter-pull under the carrier layer.

Verfahren 2Method 2

Eine Dekorschicht wird in einem ersten Arbeitsgang hergestellt / verpresst. Auf diese Oberschicht wird die flüssige Polyurethanmischung aufgetragen und ausgehärtet. Vorzugsweise wird als Gegenzug eine Stabilisierungslage integriert.A decorative layer is produced / pressed in a first operation. On top of this layer, the liquid polyurethane mixture is applied and cured. Preferably, a stabilization layer is integrated as a countermove.

Verfahren 3Method 3

Eine Trägerschicht aus Polyurethan wird in einem ersten Arbeitsgang hergestellt. Auf diese Trägerschicht wird das Pudergemisch aufgetragen und in einer Presse unter Temperatureinwirkung und Druck miteinander verpresst. Das heißt, in einem Arbeitsgang wird die Oberschicht hergestellt und gleichzeitig mit der Trägerplatte verbunden. Vorzugsweise enthält die PUR-Trägerschicht ober- und unterseitig Funktionslagen, die eine Verpressung und sichere Verbindung in einer Presse mit Hitze und Druck zwischen der Oberschicht und der Trägerschicht ermöglichen.A backing layer of polyurethane is produced in a first operation. On this carrier layer, the powder mixture is applied and in a press under Temperature effect and pressure pressed together. That is, in one operation, the top layer is made and simultaneously connected to the carrier plate. Preferably, the PUR support layer contains top and bottom functional layers that allow a compression and secure connection in a press with heat and pressure between the top layer and the carrier layer.

Claims (14)

  1. Plate-shaped component, in particular a floor panel, having an upper layer which is arranged on the upper side of a carrier layer, wherein the upper layer is formed from a mixture of fibrous and/or powdery wood material, binder and colour pigments, which mixture is pressed under the action of temperature and pressure and the carrier layer is formed from a polyurethane basis, characterised in that at least one functional layer which consists of a veneer, in particular a real wood veneer, is integrated into the upper layer.
  2. Plate-shaped component according to claim 1, characterised in that the upper layer and the carrier layer are pressed together.
  3. Plate-shaped component according to claim 1 or 2, characterised in that the upper layer and the carrier layer are bonded together.
  4. Plate-shaped component according to any of claims 1 to 3, characterised in that the carrier layer contains fillers, additives and/or dyes.
  5. Plate-shaped component according to any of claims 1 to 4, characterised in that a stabilising layer, in particular a fleece, grid or fabric layer, is incorporated.
  6. Plate-shaped component according to claim 5, characterised in that the stabilising layer is integrated into the carrier layer.
  7. Plate-shaped component according to claim 5, characterised in that the stabilising layer is arranged under the carrier layer.
  8. Plate-shaped component according to any of claims 1 to 7, characterised in that the carrier layer is profiled on the edge side and provided with locking means.
  9. Plate-shaped component according to any of claims 1 to 8, characterised in that it has a weight per unit area of greater than or equal to (≥) 4.0 kg/m2, in particular greater than or equal to (≥) 5.0 kg/m2.
  10. Plate-shaped component according to any of claims 1 to 9, characterised in that it has a total thickness of 3.0 mm to 7.5 mm, in particular of 4.0 to 5.0 mm.
  11. Plate-shaped component according to any of claims 1 to 10, , characterised in that the visible surface is ground, embossed, brushed and/or sealed.
  12. Plate-shaped component according to any of claims 1 to 11, characterised in that the visible surface is printed with a decoration.
  13. Plate-shaped component according to any of claims 1 to 12, characterised in that the visible surface has different degrees of gloss.
  14. Plate-shaped component according to any of claims 1 to 13, characterised in that the carrier layer is heat-resistant and non-destructively withstands temperatures of up to 200 °C, in particular up to 160 °C, for 30 seconds.
EP17158827.0A 2016-03-18 2017-03-02 Plate-shaped building element Active EP3235970B1 (en)

Applications Claiming Priority (1)

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DE102016105046.6A DE102016105046A1 (en) 2016-03-18 2016-03-18 Plate-shaped component

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
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DE3005707A1 (en) 1980-02-15 1981-08-20 Streif Ohg, 5461 Vettelschoss LARGE-SIZED BUILDING BOARD AND METHOD FOR THE PRODUCTION THEREOF, AND WALL ELEMENT COMPOSED FROM THESE BOARDS
DE29620751U1 (en) * 1996-11-29 1997-01-23 Solarek, Lutz, 01640 Coswig Composite panel
DE19944399A1 (en) * 1999-09-16 2001-04-12 Wpt Gmbh Polymertechnik Floor element with at least one cover layer, for floor superstructures, comprises carrier layer which comprises polyurethane or acrylate as a bonding agent with embedded filler materials
DE102004003457A1 (en) * 2003-12-04 2005-07-28 Hamberger Industriewerke Gmbh tile
DE102005061222A1 (en) 2005-12-20 2007-06-21 Dynea Erkner Gmbh Vegetable fiber, fiber-based shaped articles and methods of making novolak-treated vegetable fibers
DE102006058655B4 (en) 2006-12-11 2010-01-21 Ulrich Windmöller Consulting GmbH floor panel
DE102009000717A1 (en) 2009-02-09 2010-08-12 Wacker Chemie Ag Nature / plastic sheet
KR101875588B1 (en) 2010-01-15 2018-07-06 뵈린게 이노베이션 에이비이 Bright colored surface layer
PL2616250T3 (en) * 2010-09-14 2016-12-30 Interior fitting component for cladding and process for producing an interior fitting component
PL2755818T3 (en) 2011-10-31 2015-07-31 Wpt Gmbh Elastic floor covering
DE202011107844U1 (en) * 2011-11-15 2013-02-18 Surface Technologies Gmbh & Co. Kg Panel with edge break
PT2777928T (en) * 2013-03-15 2016-10-18 Ecore Int Inc Recycled rubber backed cushioned vinyl
DE102013113478A1 (en) 2013-12-04 2015-06-11 Guido Schulte Floor, wall or ceiling panel and method of making the same

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Publication number Publication date
EP3235970A1 (en) 2017-10-25
DE202017006916U1 (en) 2018-10-30
DE102016105046A1 (en) 2017-09-21
DE202017006917U1 (en) 2018-10-30
EP3235973B1 (en) 2018-10-17
EP3235973A1 (en) 2017-10-25

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