EP3544823A1

EP3544823A1 - Carrier material for a decorated wall or floor panel

Info

Publication number: EP3544823A1
Application number: EP17801481.7A
Authority: EP
Inventors: Hans-Jürgen HANNIG; Egon Hoff
Original assignee: Akzenta Paneele and Profile GmbH
Current assignee: Akzenta Paneele and Profile GmbH
Priority date: 2016-11-25
Filing date: 2017-11-24
Publication date: 2019-10-02
Also published as: US20200164561A1; US11279070B2; WO2018096104A1; CN110225832A; EP3326835A1

Abstract

The invention relates to a carrier material for producing a carrier (12) for a decorated wall or floor panel (10), wherein the carrier material (14) comprises a matrix material having a plastic, a solid material and a fiber material, wherein the solid material is formed by an inorganic material in a proportion of at least 50 wt.%, in particular at least 80 wt.%, in particular at least 95 wt.% in relation to the solid material, wherein the matrix material is present in a quantity of ≥ 20 wt.% to ≤ 60 wt.%, in particular ≥ 28 wt.% to ≤ 48 wt.%, in particular ≥ 35 wt.% to ≤ 41 wt.% in relation to the carrier material, and wherein the solid material is present in a quantity of ≥ 25 wt.% to ≤ 65 wt.%, in particular ≥ 33 wt.% to ≤ 53 wt.%, in particular ≥ 40 wt.% to ≤ 46 wt.% in relation to the carrier material, and wherein the fiber material is present in a quantity of > 1 wt.% to ≤ 35 wt.%, in particular ≥ 7 wt.% to ≤ 30 wt.%, approximately ≥ 14 wt.% to ≤ 21 wt.% in relation to the carrier material, and wherein the matrix material, the fiber material and the solid material together are present in a quantity of ≥ 89 wt.%, approximately ≥ 95 wt.%, in particular ≥ 97 wt.% in relation to the carrier material (20).

Description

Carrier material for a decorated wall or floor panel

The present invention relates to a carrier material for producing a decorated wall or floor panel. The present invention further relates to a decorated panel comprising such a substrate and to a method of making a decorated wall or floor panel.

Decorated panels are known per se, wherein the term wall panel also includes panels that are suitable for ceiling or door clothing. They usually consist of a carrier or core made of a solid material, for example a wood material, which is provided on at least one side with a decorative layer and a cover layer and optionally with other layers, for example, arranged between the decorative and cover layer wear layer. The decorative layer is usually a printed paper impregnated with a resin. The top layer and the remaining layers are usually made of resin. DE 20 2016 101 306 U1 describes a carrier material for producing a carrier for a decorated wall panel or floor panel, wherein the carrier material comprises a matrix material comprising a plastic and a solid material, wherein the solid material comprises at least 50% by weight, in particular at least 80% by weight .-%, in particular at least 95 wt .-%, based on the solid material, is formed by talc, wherein the matrix material in an amount, based on the carrier material, from> 30 wt .-% to <

70 wt .-%, in particular from> 40 wt .-% to <60 wt .-%, and wherein the

Solid material, based on the support material, in an amount based on the CD 41739 /: UAM Carrier material, from> 30 wt .-% to <70 wt .-%, in particular from> 40 wt .-% to <60 wt .-%, is present, and wherein the carrier material and the solid material together, based on the carrier material, in an amount of> 95% by weight, in particular> 99% by weight. However, there is no reference in this document to the use of fibers in the substrate.

US 2006/264544 A1 further describes fiber-reinforced polypropylene compositions which, in addition to polypropylene, comprise an organic reinforcing fiber, an inorganic filler and a dye. However, this document gives no indication of the use of a composition as a support material for a floor panel.

From the document EP 2 829 415 AI a method for the production of a decorated wall or floor panel is known in which, starting from a granular carrier material, a carrier and then a panel is formed. In such a method, for example, a WPC can be used as a carrier material.

The document DE 35 11 046 C2 describes an antistatic, heat and pressure-strengthened laminate, consisting of a lower core layer, which has a plurality of fibrous layers, and a cover layer contained on the core layer arranged decorative cellulose fibers.

Such solutions may still offer room for improvement. Potential for improvement can be found in particular in terms of stability, moisture resistance and heat resistance.

It is therefore the object of the present invention to provide an improved wall or floor panel and / or a method for producing the same. This object is achieved by a support material according to claim 1. This object is further achieved by a panel according to claim 11 and by a method according to claim 12. Preferred embodiments of the invention are specified in the subclaims, in the description or the figures, wherein further in The features described or shown in the description or the figures, individually or in any combination, may constitute an object of the invention, unless the context clearly indicates otherwise.

The invention proposes a carrier material for producing a carrier for a decorated wall or floor panel. The carrier material has a plastic material containing matrix material, a solid material and a fiber material, wherein the solid material to at least 50 wt .-%, in particular at least 80 wt .-%, in particular at least 95 wt .-%, for example> 99 wt. % based on the solid material, by an inorganic, such as mineral material, such as talcum talcum formed, wherein the matrix material in an amount, based on the carrier material, from> 20 wt .-% to <60 wt .-%, in particular from> 28 wt .-% to <48 wt .-%, in particular from> 35 wt .-% to <41 wt .-%, and wherein the solid material, based on the carrier material, in an amount of> 25 wt % to <65 wt .-%, in particular from> 33 wt .-% to <53 wt .-%, in particular from> 40 wt .-% to <46 wt .-%, and wherein the fiber material, based to the carrier material, in an amount of> 1 wt .-% to <35 wt .-%, in particular of> 7 wt .-% to <30 wt .-%, from about> 14 wt .-% to <21 wt .-%, is present, and wherein the matrix material, the fiber material and the solid material together, based on the carrier material (20), in an amount of> 89 wt .-%, for example of> 95 wt .-%, in particular> 97 wt .-%, are present.

It could be shown in a surprising manner that such a carrier material allows the production of a wall or floor panel with a very good stability, wherein Furthermore, a very good moisture resistance can be made possible, in particular with a reduced moisture or heat-induced swelling.

The aforementioned carrier is used in particular for use in a decorated wall or floor panel.

For the purposes of the invention, the term "decorated wall or floor panel" or "decorative panel" is to be understood, in particular, as wall, ceiling, door or floor panels, which have a decorative pattern applied to a carrier panel and a decoration pattern. Decorative panels are used in a variety of ways, both in the field of interior design of rooms, as well as decorative cladding of buildings, for example in exhibition construction. The decorative panels often have a decor that is intended to recreate a natural material. Examples of such modeled natural materials or decorative patterns are wood species such as maple, oak, birch, cherry, ash, walnut, chestnut, wenge or exotic woods such as panga panga, mahogany, bamboo and bubinga. In addition, many natural materials are modeled on stone surfaces or ceramic surfaces.

Correspondingly, a "decor template" in the sense of the present invention may be understood as meaning, in particular, such an original natural material or at least a surface of one which is to be imitated or imitated by the decor.

A "carrier" may, in particular, be understood as a layer serving as a core or as a base layer in a finished panel, for example, the carrier may already provide or contribute to the panel a suitable stability. Accordingly, a carrier material can be understood as meaning a material which forms the carrier at least to a predominant part. In particular, the carrier can consist of the carrier material.

Furthermore, the term inorganic is in particular a collective term for the chemical elements other than the carbon, for the carbon-free compounds, with the exception of the carbon oxides carbon dioxide and carbon monoxide, as well as the carbonates and carbides and for systems or processes of inanimate nature.

A prescribed carrier material has a plastic material containing matrix material, a solid material and a fiber material.

The matrix material serves, in particular, to take up or embed the solid material and the fiber material in the finished carrier. The matrix material in this case has a plastic or a plastic mixture.

Depending on the desired field of application and the desired properties of the panel, the proportions of matrix material, fiber material and solid material may be selectable. As a result, good adaptability to the desired field of application becomes possible. In principle, however, it may be preferred that the proportion of the solid material is greater than or equal to the proportion of the matrix material and that the proportion of the fiber material is less than the proportion of the matrix material and less than the proportion of the solid material.

With regard to the plastic material, for example consisting of a plastic or a plastic mixture matrix material, it is provided that this in an amount, based on the carrier material, from> 20 wt .-% to <60 wt .-%, in particular from> 28 wt .-% to <48 wt .-%, in particular from> 35 wt .-% to <41 wt .-%, is present.

Examples of plastics which may preferably serve as matrix material include in particular thermoplastic materials, for example polyethylene or polypropylene or mixtures of the aforementioned plastics. It may further be preferred that the matrix material comprises polypropylene, wherein the polypropylene may comprise a mixture of a homopolymer and a copolymer. In particular, a mixture of a homopolymer and a copolymer may allow particularly advantageous properties for the matrix material by being able to be formed in a range of> 180 ° C to <220 ° C to a carrier, so that a particularly effective process control, such as exemplary line speeds in a range of 6m / min, can be made possible. Furthermore, the matrix material may in principle be free of a bonding agent. As a copolymer, for example, find such a use, which is composed of, for example, consists of propylene and ethylene as monomer units, wherein the density of the copolymer may be greater than or equal to the density of the homopolymer.

By using a homopolymer, in particular, a high melt flow rate can be made possible, wherein the melt flow rate of the homopolymer may in particular be greater than that of the copolymer. This can allow a particularly good formability of the carrier during the manufacturing process. Furthermore, the homopolymer can thereby allow a particularly good embedding of the solid material. In contrast, the copolymer can in particular serve the mechanical strength of the carrier material or of the carrier, since a copolymer often has a hardness that is comparatively high, in particular with respect to the homopolymer. With respect to the distribution of homopolymer and copolymer, it may be preferred that the homopolymer based on the polypropylene and optionally based on the matrix material in a proportion of> 10 wt .-% to <40 wt .-%, for example in a proportion of > 20 wt .-% to <30 wt .-%, and / or that the copolymer based on the polypropylene in a proportion of> 60 wt .-% to <90 wt .-%, for example in a proportion of> 70 Wt .-% to <80 wt .-%, in particular wherein the polypropylene consists of the homopolymer and the copolymer.

It may further be preferred that the matrix material comprises a mixture of polypropylene and polyethylene. The polypropylene may in particular be a homopolymer. The polyethylene can be configured in particular as HDPE. The mixing ratio may be, for example, in a range of from 40% by weight to 60% by weight to 60% by weight to 40% by weight, for example in a range of 50% by weight, in a range from polypropylene to polyethylene. to 50% by weight. To obtain a particularly homogeneous mixture and a stable carrier, the provision of a coupling agent may be particularly preferred in this case. As such, for example, can serve a copolymer of polyethylene and polypropylene.

The solid material is, based on the carrier material, in an amount of> 25 wt .-% to <65 wt .-%, in particular from> 33 wt .-% to <53 wt .-%, in particular of> 40 wt. % to <46 wt .-%, before.

With regard to the solid material, this may have a particle size of less than 800 μm, preferably less than 600 μm. As a result, the solid can be distributed very finely in the matrix material.

The solid or the solid material is formed as an inorganic solid material. Examples include particularly preferably talc, or else chalk, wollastonite, stone meal or other minerals. It may be particularly preferred if the solid comprises talcum, for example consists thereof. With regard to the use of talc as a solid, it may be advantageous that, in particular in this embodiment, a high stability can be made possible. In addition, such a carrier material can allow improved moisture resistance, in particular with a reduced moisture or heat-induced swelling. Under talc is understood in a conventional manner, a magnesium silicate hydrate, which may have, for example, the chemical empirical formula Mg3 [Si40io (OH) 2]. It may be advantageous if the specific surface density according to ISO 4352 (BET)) of the talcum particles is in a range from> 4 m ² / g to <8 m ² / g, approximately in a range of> 5 m ² / g to <7 m ² / g. Furthermore, it may be advantageous if the talcum is present at a bulk density according to DIN 53468 in a range of> 0.15 g / cm ³ to <0.45 g / cm ³ , approximately in a range of> 0.25 g / cm ³ to <0.35 g / cm ³ . It may preferably be provided that talcum is present in the form of particles having a particle size D50 in a range from> 3μιη to <6μιη, preferably in a range of> 4μιη to <5μιη, for example of 4.5 μιη, and / or the talcum is present in the form of particles having a particle size D98 in a range of> ΙΟμιη to <30μιη, preferably in a range of> 15μιη to <20μιη, for example of 17 μιη. In order to determine the particle size distribution, basically the generally known methods, such as, for example, laser diffractometry, can be used, with which particle sizes in the range of a few nanometers up to several millimeters can be determined. This method can also be used to determine D50 or D98 values, which in each case indicate that 50% (D50) or 98% (D98) of the measured particles are smaller than the value specified in each case. As another solid may be, for example, a wood material, such as wood flour, or other material, such as a component of the rice plant, such as the rice spelled, the rice stem and the rice husk or cellulose. With regard to the use of wood as a solid, it is therefore possible to design a so-called WPC carrier, which is basically known and has great acceptance. Thus, in particular in this embodiment, a carrier according to the invention can take place by a modification of known products. For example, for wood, in particular for wood flour, it may be provided that its particle size is between> 0μιη and <600μιη with a preferred particle size distribution D50 of> 400μιη.

In principle, the solids may not be in the form of chips, chips or grains, that is to say in the form of powder, in a limiting manner.

In a particularly preferred embodiment, it may be advantageous that the solid material to at least 50 wt .-%, about at least 80 wt .-%, in particular about at least 90 wt .-%, for example, at least 99 wt .-% relative is formed on the solid material by inorganic solids such as talc.

With regard to the above-described fiber material provided in the carrier material, it is provided that this fiber material in the carrier material, based on the carrier material, in an amount of> 1 wt .-% to <35 wt .-%, in particular of> 7 wt .-% to <30 wt .-%, for example from> 14 wt .-% to <21 wt .-%, is present. It has been shown that in the case of a previously described carrier material which, as main constituents, has the matrix material and the solid material in addition to the fiber material, a significantly increased stability can be present. In particular, it has been shown that the fracture value of a carrier or a panel, which is or is formed from such a carrier material, can be significantly increased. As a result, the stability can be significantly increased even if the fiber material in the carrier material in comparatively small amounts, such as, based on the carrier material, in an amount of> 14 wt .-% to <21% by weight, in particular> 15 wt .-% to <20 wt .-%, is present. As a result, further properties of the carrier, such as a suitable impact sound insulation or the like, can be retained, which may allow a particularly advantageous property profile of a carrier configured from such a carrier material.

The same applies to a significant improvement in deformation under permanent load, which can be represented for example in the so-called wheelchair test. In particular, such improved stability against deformation may be advantageous in terms of long-term stability, which may allow a very good appearance and a very good feel even after a comparatively long use of the panel.

In addition, it has been found that a previously described carrier material allows the production of a carrier, as described in detail below, wherein the carrier has a particularly good and in particular smooth surface. This can be advantageous in particular for the application of a decoration or a decorative layer, for example when the decor is printed, as described in detail below. In particular, in this embodiment, a high-quality surface image of the decor can be made possible.

Basically, the mechanical properties, such as with respect to the tensile modulus, the bending modulus, the tensile strength, the elongation at break, the bending stress of the Ball pressure hardness and impact resistance are all advantageously designed for a floor panel.

It may be particularly preferred that the fiber material comprises fibers having a length in a range of> 1 mm to <10 mm, preferably in a range of> 3 mm to <7 mm. Surprisingly, it has been found that such fibers can provide high stability, but with significant advantages in manufacturability. In this case, such a configuration further offers the advantage of improved manufacturability. For it has surprisingly been found that in particular a pretreatment of the carrier material or a production thereof in an extruder using a fiber material in this length range can be carried out particularly advantageously and without problems.

Basically, as is known per se, the fibers have a diameter or a thickness which is smaller than the length, in particular smaller than the aforementioned length ranges. It may be particularly preferred that the fiber material comprises fibers having a maximum diameter of <ΙΟΟμιη, for example from> 9 μιη to <ΙΟΟμιη example of>

More preferably, the fibers may have a thickness in a range of> ldtex to <10 dtex, for example in a range from> 1, 2dtext to <8.5 dtex. This embodiment can also allow a significant improvement in stability, in particular in the previously defined carrier material with matrix material, solid material and fiber material in the proportions described above, wherein a processability by the Presence of the fibers is not or not significantly deteriorated. Thus, even in this embodiment, a very high quality product without production-specific disadvantages can be made possible. It may further be preferred that the fiber material comprises fibers selected from the group consisting of vegetable, animal, mineral or even artificial fibers. Examples of vegetable fibers include, for example, cellulose fibers, lignose fibers, as well as fibers from straw, corn straw, bamboo, leaves, algae extracts, hemp, cotton or oil palm fibers. Examples of animal fiber materials are keratin-based materials such as wool or horsehair. From the aforementioned fibers, for example, cellulose may be of particular advantage. Examples of mineral fiber materials are mineral wool or glass wool.

Examples of artificial fibers include, for example, glass fibers or plastic fibers such as polyester fibers, with polyethylene terephthalate (PET) fibers as polyester fibers being particularly preferred because of their processability and the stability properties of the carrier produced. For example, polyester fibers can be obtained by dicing, such as chopping, polyester nonwoven. Other fibers may be those of polycarbonate, polyethylene or polyamide or LCP fibers pder polyacrylonitrile fibers.

Plant and animal fibers may have the advantage of a particularly good ecological balance, whereas mineral fibers or artificial fibers may have advantages in terms of heat and moisture resistance.

Insofar as the fiber material comprises synthetic fibers, it may be advantageous that the melting temperature of the plastic fibers is higher than the melting temperature of the matrix material. This configuration can in turn manufacture-specific advantages to bring oneself. For producing a carrier from the predefined carrier material, it may be advantageous to melt the carrier material or the matrix material and to form a carrier under pressure, as described below. In this embodiment, it can be prevented in such a process that the plastic fibers also melt, which could at least partially cancel the above-described advantages of the fiber material. Thus, in particular in this embodiment, a well processable manufacturing process can be made possible while ensuring the desired properties. Exemplary plastic fibers include, for example, the aforementioned artificial or polymeric fibers.

By limiting the materials of the carrier material and thus by a small number of materials for producing the carrier, the carrier can be produced particularly inexpensively. In addition, the process management of the production of a carrier or a panel can be very simple, so that the production is easy and free of charge.

A carrier described above, in particular with an inorganic, for example mineral, material, such as talc as a solid in a matrix material, as described above, furthermore offers the particular advantage of good moisture resistance. In particular, using a carrier material as described above, it can be significantly reduced or even completely prevented that a panel produced from the carrier material swells when exposed to moisture. Furthermore, an improved heat resistance can also be given, that is to say a heat-induced expansion is prevented or at least significantly reduced, and the use of talcum can furthermore have advantages with respect to the modulus of elasticity, the creep resistance. Thus, it may be advantageous that the carrier material consists to a large extent of the solid material and the matrix material and the fiber material. Particularly preferably, it can be provided that the matrix material and the fiber material and the solid material together, based on the carrier material, in an amount of> 89% by weight, for example> 97 wt .-%, approximately in an amount of 100 wt .-%, are present, the carrier material thus consists of the matrix material and the solid material and the fiber material.

The carrier material may particularly preferably comprise a polymeric, in particular thermoplastic, plastic, for example as a plastic mixture, for example polypropylene as a mixture of a homopolymer and a copolymer as described above, as matrix material, talc as solid material and polyester fibers as fiber material. In particular, in this embodiment, a production can be particularly cost-effective and process management can be particularly simple. Incidentally, the weight ratio of polypropylene to talc to polyester fibers may be 33 to 43:17, and the above components may constitute 89% by weight to 100% by weight of the carrier material.

Furthermore, the support material may optionally have between> 0 wt .-% and <11 wt .-% of other additives, such as flow aids, heat stabilizers or UV stabilizers. By way of example, as additives of in principle> 0% by weight, for example at least one or any selection of a processing stabilizer in a content of 0.2-08% by weight, about 0.5% by weight, of an adhesion promoter in a content from 1-4% by weight, about 2.5% by weight, of a UV stabilizer in a content of 1-4% by weight, about 2.5% by weight and a flow aid in a content of 1-2 wt .-%, about 1.5 wt .-%, each based on the carrier material, are present. The support material has the advantage that panels produced thereby have a very good stability, so that the risk of damage to the panel during transport and during use are extremely low. This can be achieved in particular by the solid material, ie in particular by the inorganic material contained.

A carrier made of the carrier material can continue to be provided with a decoration without any problems. For example, such a carrier is very suitable for printing, in particular with a digital printing method, for example an inkjet printing method. As a result, such carriers can be easily provided with a high-quality decor, which can allow the production of a high-quality panel.

With regard to further technical features and advantages of the carrier, reference is hereby explicitly made to the description of the panel, the method and to the figures.

The present invention further relates to a decorated panel, in particular a decorated wall or floor panel, comprising a carrier and a decorative layer applied to the carrier, in particular wherein a cover layer provided with a structure is applied to the decorative layer. Such a panel is characterized in that the carrier is configured as described in detail above. With respect to the specific features, reference is therefore made to the above description.

The edge regions of the panel can be structured or profiled to provide in particular detachable connecting elements. In this regard, in the case of a profiling according to the invention it can be provided that a decorative and / or functional profile is introduced by means of suitable material-removing tools at least into a part of the edges of the decorative panel. It is under a functional Profile to understand, for example, the introduction of a tongue and / or groove profile in an edge to make decorative panels connected to each other via the introduced profilings. Particularly in the case of tongue and / or groove profiles, elastic materials are advantageous, since such profiles alone can be produced by them, which are particularly easy to handle and stable. In particular, no further materials are necessary to produce the fasteners.

In summary, the above-described panel can offer the advantage of high dimensional stability with respect to heat and moisture flow, with at the same time good mechanical properties or good mechanical stability and light weight. Furthermore, such a panel can be very stable and at the same time have a high degree of elasticity, which can be advantageous in particular for an effective and cost-effective design of connecting elements on the edge area of the carrier and furthermore with regard to footfall sound insulation.

With regard to further technical features and advantages of the panel, reference is hereby explicitly made to the description of the carrier material, the method and to the figures.

The subject matter of the present invention is furthermore a method for producing a decorated wall or floor panel, comprising the method steps:

a) providing a pourable carrier material, as described in detail above,

b) in particular arranging the carrier material between two belt-like conveying means, c) shaping the carrier material under the action of temperature and pressure to form a carrier, in particular a sheet-like carrier,

d) optionally cooling the support,

e) optionally applying a decorative substrate to at least a portion of the carrier; f) application of a decorative template replica decorative layer on at least a portion of the carrier, and

g) applying a cover layer on at least a portion of the decorative layer. As will be readily apparent to those skilled in the art, process steps a) to c) serve to produce a support for a decorated wall or floor panel, that is, for a defined part of a method of making a decorated wall or floor panel, the latter being characterized by the additional Steps d) to g) can be completed. With regard to the advantages of the carrier, reference is made to the above description.

In accordance with method step a), provision is thus made of a granular carrier material, wherein the carrier material comprises a plastic-containing matrix material, a fiber material and a solid material. The granular carrier material can be provided in prefabricated carrier material particles, wherein the particles already comprise melted solid material and fiber material in the matrix material. Such carrier material particles may be obtainable, for example, by an extrusion process.

In other words, it can be provided that method step a) comprises the processing of a raw material mixture in an extruder, in particular a twin-screw extruder. In this case, particles of the carrier material can arise, which have a maximum diameter in the millimeter range, for example in a range of> 1 mm to <10 mm.

In this regard, it can be provided that method step a) comprises that the matrix material, the fiber material and the solid material are each introduced into an extruder as an independent or respectively different phase and processed there as a raw material mixture. In this embodiment, therefore, a mixture of the fiber material, the matrix material and the solid material in the extruder obtained and obtained by further processing particles of the carrier material. This embodiment can allow a particularly simple process control and thereby a particularly simple adaptability. The latter applies in particular if the ratio of the individual components to one another is to be changed.

Alternatively it can be provided that method step a) comprises placing a prefabricated composite material of the fiber material and the matrix material in the extruder and processing it in the extruder with the solid material as raw material mixture. In this embodiment, therefore, first the fiber material is incorporated into the matrix material to obtain a composite material comprising the matrix material with fiber material distributed therein. This composite material can then be mixed with the solid material in the extruder and processed. It has surprisingly been found that, in particular in this embodiment, a carrier can be formed, which has a particularly smooth surface and is therefore particularly suitable for the subsequent application of a decorative layer. In addition, this embodiment can manage with a smaller number of scattering heads, which can bring benefits in terms of plant technology.

It may also be preferred that the fibers are inserted into a region of the extruder in which only insignificant shear forces are applied. This can counteract damage to the fibers.

A granular carrier material may be understood as meaning a solid or a heap of a solid which comprises or consists of a large number of solid particles, such as grains or spheres. By way of example, but not exhaustive, granular or pulverulent materials may be mentioned here. The carrier material is the material from which the carrier is designed, in particular from which Carrier exists. With regard to the carrier material used is described in the above description of the panel.

According to process step b), the carrier material is arranged between two belt-like conveying means and shaped according to process step c) under the action of temperature and pressure to form a web-shaped carrier.

For example, the granular carrier material can be arranged between two belt-like conveying means, which are moved circumferentially, so that between the conveying means the carrier can be formed by the action of pressure and heat, in particular with at least partial melting of the matrix material. The carrier material can be applied to the lower conveyor and then limited by the lower and the upper conveyor. For example, the conveying means may pass through one or a plurality of pressing devices and heating devices and, if appropriate, cooling devices, in order to be able to form the carrier in a suitable manner. The band-like conveying means may be at least partially made of polytetrafluoroethylene (PTFE). For example, the bands may be formed entirely of polytetrafluoroethylene, or glass fiber reinforced plastic bands or steel bands with a polytetrafluoroethylene coating may be used.

In a further step, for example, after arranging the carrier material, a shaping of the carrier material arranged between the belt-like conveying means takes place under the action of temperature or heat. In this method step takes place by the applied heat or heat thus melting or softening of the carrier material or at least part thereof, whereby, for example, the granules can be formed. In this state, it can fill the receiving space forming between the conveying means and thus form an approximately web-shaped support which can be further treated. As pressing means, for example, rollers and / or a two-belt press can be used. In so far as a two-belt press is used as a pressing device, in this as a final pressing step in the carrier production in particular the surface properties of the carrier with low pressure and low compression can be adjusted in a very small range, such as a compression of> 0% to <7%, for example <5%.

After passing through the pressing and / or heating devices, such as a two-belt press, the carrier produced can be stored in web-like form or as an isolated plate-like carrier as an intermediate product and the process can be terminated first. Preferably, however, immediately follow further treatment steps. To produce a finished panel, the previously produced carrier is subsequently provided with a decoration or a decorative layer and this is coated with a protective layer or a wear or cover layer.

In order to apply a decor or a decorative layer, first of all, according to method step e), a decorative substrate can be applied to at least one subregion of the carrier. For example, initially a primer can be applied in particular for printing processes as a decorative substrate, for example in a thickness of> ΙΟμιη to <60 μιη. In this case, a liquid radiation-curing mixture based on a urethane or a urethane acrylate, optionally with one or more of a photoinitiator, a reactive diluent, a UV stabilizer, a rheology agent such as a thickener, radical scavenger, flow control agent, defoamer or preservative, pigment and / or or a dye. In addition to the primer, a white colored primer may be applied. For example, the primer may have polyurethane, be designed as a polyurethane varnish, for example, and be provided with white pigments. In addition to the use of a primer, it is possible to apply the decor to a decorative paper which can be printed with a corresponding decor, which can be provided as a connection means, for example, by means of a resin layer previously applied to the support. Further, on the paper, a resin may be applied as a printing substrate, which as a resin component may have at least one compound selected from the group consisting of melamine resin, formaldehyde resin, urea resin, phenolic resin, epoxy resin, unsaturated polyester resin, diallyl phthalate or mixtures thereof.

Subsequently, the decor or the decorative layer according to method step f) can be generated in particular by a printing process, which are suitable both for flexographic printing, offset printing or screen printing methods, and in particular digital printing techniques, such as Inkj et- method or laser printing method. The decorative layer can be formed from a particular radiation-curable ink and / or ink. For example, a UV-curable ink or ink may be used. It is also possible, if appropriate, first to carry out pretreatment of the carrier for electrostatic discharge and, if appropriate, subsequent electrostatic charging, before printing. This may in particular serve to avoid the occurrence of blurring in the course of decor application. With regard to the wearing or covering layer, which is applied according to method step g), above the decorative layer, it may be provided that it is laid on the printed support as a pre-produced overlay layer, for example based on melamine, and bonded thereto by pressure and / or heat becomes. Further For example, it may be preferred that a radiation-curable composition, such as, for example, a radiation-curable lacquer, such as an acrylic lacquer, is also applied to form the wear and / or cover layer. It may be provided that the wear layer hard materials such as titanium nitride, titanium carbide, silicon nitride, silicon carbide, boron carbide, tungsten carbide, tantalum carbide, aluminum oxide (corundum), zirconium oxide or mixtures thereof, to increase the wear resistance of the layer. In this case, the application can be applied for example by means of rollers, such as rubber rollers or by means of pouring devices. In particular, a structuring, in particular a surface structuring matching the decor, can be introduced into the cover layer by the introduction of pores. This can be realized, for example, by imprinting corresponding structures. It may be particularly preferred if the cover layer is printed on the surface, for example by means of an inkjet printer, and / or by a multiple application, since highly accurate structures can thus be produced.

The invention is explained below with reference to the figure and an embodiment.

Fig. 1 shows schematically a view of a decorated panel with a carrier 12 made of a carrier material according to the invention. FIG. 1 schematically shows a view of a decorated wall or floor panel 10. The wall or floor panel 10 includes a support 12 formed from a substrate 14. In this case, it is provided that the carrier material 14 has a plastic material containing matrix material, a solid material and a fiber material, wherein the solid material to at least 50 wt .-%, in particular at least 80 wt .-%, in particular at least 95 wt .-% , based on the solid material, is formed by an inorganic material, in particular by talc, wherein the matrix material in an amount, based on the carrier material, of> 20 wt .-% to <60 wt .-%, in particular of> 28 wt % to <48 wt .-%, in particular from> 35 wt .-% to <41 wt .-%, and wherein the solid material, based on the carrier material, in an amount of> 25 wt .-% to < 65 wt .-%, in particular from> 33 wt .-% to <53 wt .-%, in particular from> 40 wt .-% to <46 wt .-%, and wherein the fiber material, based on the carrier material, in an amount of from> 1% by weight to <35% by weight, in particular from> 7% by weight to <30% by weight, from> 14% by weight to <21 wt .-%, is present, and wherein the matrix material, the fiber material and the solid material together, based on the carrier material (20), in an amount of> 89 wt .-%, about> 95 wt .-%, in particular > 97 wt .-%, are present.

On the support 12, a printing substrate 16 is provided, which serves as a substrate for a particular printed decorative layer On the decorative layer 18, a cover layer 20 is provided which may be constructed in multiple layers and may have a structure that matches the decor of the decorative layer 18.

Reference numerals:

10 wall or floor panel

12 carriers

14 carrier material

16 printing substrate

18 decorative layer

20 topcoat

Claims

claims

A backing material for making a backing (12) for a decorated wall or floor panel (10), said backing material (14) comprising a matrix material comprising a plastic, a solid material and a fibrous material, said solid material being at least 50% by weight. , in particular at least 80 wt .-%, in particular at least 95 wt .-%, based on the solid material, is formed by an inorganic material, wherein the matrix material in an amount, based on the carrier material, of> 20 wt .-% to <60 wt .-%, in particular from> 28 wt .-% to <48 wt .-%, in particular from> 35 wt .-% to <41 wt .-%, is present and wherein the solid material, based on the carrier material , in an amount of> 25% by weight to <65% by weight, in particular of> 33% by weight to <53% by weight, in particular of> 40% by weight to <46% by weight , and wherein the fiber material, based on the carrier material, in an amount of> 1 wt .-% to <35 wt .-%, in particular of> 7 wt .-% to <30 wt .-%, for example from> 14 wt .-% to <21 wt .-%, is present, and wherein the matrix material, the fiber material and the solid material together, based on the carrier material (20) , in an amount of> 89% by weight, about> 95% by weight, in particular> 97% by weight.

2. Carrier material according to claim 1, characterized in that the fiber material comprises fibers having a length in a range of> 1 mm to <10 mm, wherein the length is greater than the diameter.

3. Support material according to claim 1 or 2, characterized in that the fiber material comprises fibers having a diameter in a range of <ΙΟΟμιη, for example from> 9 μιη to <ΙΟΟμιη, wherein the diameter is smaller than the length.

4. Supporting material according to one of claims 1 to 3, characterized in that the fiber material comprises fibers having a thickness in a range of> ldtex to <10 dtex, for example in a range of> l, 2dtext to <8.5 dtex.

5. Carrier material according to one of claims 1 to 4, characterized in that the fiber material comprises fibers which are selected from the group consisting of vegetable, animal, mineral or artificial fibers.

6. The carrier material according to claim 5, characterized in that the fiber material comprises plastic fibers, wherein the melting temperature of the plastic fibers is higher than the melting temperature of the matrix material.

7. carrier material according to one of claims 1 to 6, characterized in that the matrix material comprises talc.

8. The carrier material according to any one of claims 1 to 7, characterized in that the matrix material comprises polypropylene, wherein the polypropylene comprises a mixture of a homopolymer and a copolymer.

9. Support material according to claim 8, characterized in that the homopolymer, based on the polypropylene, in a proportion of> 10 wt .-% to <40 wt .-%, for example in a proportion of> 20 wt .-% to < 30 wt .-%, and / or that the copolymer based on the polypropylene in a proportion of> 60 wt .-% to <90 wt .-%, for example in a proportion of> 70 wt .-% to <80 Wt .-%, is present.

10. Support material according to one of claims 1 to 9, characterized in that the matrix material comprises a mixture of polypropylene and polyethylene.

11. Decorated panel, in particular a decorated wall or floor panel (10), comprising a carrier (12) and a decorative layer (18) applied to the carrier (12), in particular wherein on the decorative layer (18) a cover layer provided with a structure ( 20) is applied, characterized in that the carrier (12) comprises a carrier material (14) according to one of claims 1 to 10.

12. A method for producing a decorated wall or floor panel (10), comprising the method steps:

a) providing a pourable carrier material (14) according to one of claims 1 to 10,

b) in particular arranging the carrier material (14) between two belt-like conveying means,

c) shaping of the carrier material (14) under the action of temperature and pressure to form a carrier (12), in particular a web-shaped carrier,

d) optionally cooling the carrier (12),

e) optionally applying a decorative substrate (16) on at least a portion of the support (12);

f) applying a decor template replica decorative layer (18) on at least a portion of the support (12), and

g) applying a cover layer (20) on at least a portion of the decorative layer (18).

13. The method according to claim 12, characterized in that method step a) comprises the processing of a raw material mixture in an extruder.

14. The method according to claim 13, characterized in that method step a) comprises that a prefabricated composite material of the fiber material and the Matrix material is added to the extruder and processed in the extruder with the solid material as a raw material mixture.

15. The method according to claim 13, characterized in that method step a) comprises that the matrix material, the fiber material and the solid material is introduced in each case as an independent phase in an extruder and processed there as a raw material mixture.