EP3544823A1 - Matériau de substrat pour panneau mural ou panneau de sol pourvu d'un décor - Google Patents

Matériau de substrat pour panneau mural ou panneau de sol pourvu d'un décor

Info

Publication number
EP3544823A1
EP3544823A1 EP17801481.7A EP17801481A EP3544823A1 EP 3544823 A1 EP3544823 A1 EP 3544823A1 EP 17801481 A EP17801481 A EP 17801481A EP 3544823 A1 EP3544823 A1 EP 3544823A1
Authority
EP
European Patent Office
Prior art keywords
carrier
weight
carrier material
fibers
fiber
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.)
Pending
Application number
EP17801481.7A
Other languages
German (de)
English (en)
Inventor
Hans-Jürgen HANNIG
Egon Hoff
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Akzenta Paneele and Profile GmbH
Original Assignee
Akzenta Paneele and Profile GmbH
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Akzenta Paneele and Profile GmbH filed Critical Akzenta Paneele and Profile GmbH
Publication of EP3544823A1 publication Critical patent/EP3544823A1/fr
Pending legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/15—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor incorporating preformed parts or layers, e.g. extrusion moulding around inserts
    • B29C48/154—Coating solid articles, i.e. non-hollow articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B44—DECORATIVE ARTS
    • B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
    • B44C5/00—Processes for producing special ornamental bodies
    • B44C5/04—Ornamental plaques, e.g. decorative panels, decorative veneers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C41/00—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor
    • B29C41/003—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor characterised by the choice of material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C41/00—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor
    • B29C41/24—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor for making articles of indefinite length
    • B29C41/28—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor for making articles of indefinite length by depositing flowable material on an endless belt
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/32—Component parts, details or accessories; Auxiliary operations
    • B29C43/44—Compression means for making articles of indefinite length
    • B29C43/48—Endless belts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/001—Combinations of extrusion moulding with other shaping operations
    • B29C48/0011—Combinations of extrusion moulding with other shaping operations combined with compression moulding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/07—Flat, e.g. panels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B44—DECORATIVE ARTS
    • B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
    • B44C5/00—Processes for producing special ornamental bodies
    • B44C5/04—Ornamental plaques, e.g. decorative panels, decorative veneers
    • B44C5/0453—Ornamental plaques, e.g. decorative panels, decorative veneers produced by processes involving moulding
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F13/00—Coverings or linings, e.g. for walls or ceilings
    • E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
    • E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
    • E04F13/0866—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements composed of several layers, e.g. sandwich panels or layered panels
    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2023/00—Use of polyalkenes or derivatives thereof as moulding material
    • B29K2023/10—Polymers of propylene
    • B29K2023/12—PP, i.e. polypropylene
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B29K2105/12—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of short lengths, e.g. chopped filaments, staple fibres or bristles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/732—Floor coverings
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/776—Walls, e.g. building panels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2471/00—Floor coverings
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2607/00—Walls, panels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B44—DECORATIVE ARTS
    • B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
    • B44C5/00—Processes for producing special ornamental bodies
    • B44C5/04—Ornamental plaques, e.g. decorative panels, decorative veneers
    • B44C5/0461—Ornamental plaques, e.g. decorative panels, decorative veneers used as wall coverings

Definitions

  • 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 ⁇
  • 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.
  • 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.
  • fibers in the substrate 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.
  • this document gives no indication of the use of a composition as a support material for a floor panel.
  • 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.
  • 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 ⁇
  • the aforementioned carrier is used in particular for use in a decorated wall or floor panel.
  • 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.
  • many natural materials are modeled on stone surfaces or ceramic surfaces.
  • a "decor template” in the sense of the present invention may be understood as meaning, in particular, such an original natural material or at least a surface of one which is to be imitated or imitated by the decor.
  • a “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.
  • 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.
  • 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.
  • plastic material for example consisting of a plastic or a plastic mixture matrix material
  • 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.
  • 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.
  • 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.
  • the homopolymer can thereby allow a particularly good embedding of the solid material.
  • 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.
  • 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.
  • 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.
  • 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.
  • this may have a particle size of less than 800 ⁇ m, preferably less than 600 ⁇ m. 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.
  • talc as a solid, it may be advantageous that, in particular in this embodiment, a high stability can be made possible.
  • such a carrier material can allow improved moisture resistance, in particular with a reduced moisture or heat-induced swelling.
  • talc is understood in a conventional manner, a magnesium silicate hydrate, which may have, for example, the chemical empirical formula Mg3 [Si40io (OH) 2].
  • 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 .
  • talcum is present in the form of particles having a particle size D50 in a range from> 3 ⁇ to ⁇ 6 ⁇ , preferably in a range of> 4 ⁇ to ⁇ 5 ⁇ , for example of 4.5 ⁇ , and / or the talcum is present in the form of particles having a particle size D98 in a range of> ⁇ to ⁇ 30 ⁇ , preferably in a range of> 15 ⁇ to ⁇ 20 ⁇ , for example of 17 ⁇ .
  • 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.
  • 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.
  • a carrier according to the invention can take place by a modification of known products.
  • for wood in particular for wood flour, it may be provided that its particle size is between> 0 ⁇ and ⁇ 600 ⁇ with a preferred particle size distribution D50 of> 400 ⁇ .
  • 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.
  • 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.
  • 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.
  • the fracture value of a carrier or a panel, which is or is formed from such a carrier material can be significantly increased.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • fibers can provide high stability, but with significant advantages in manufacturability.
  • such a configuration further offers the advantage of improved manufacturability.
  • 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.
  • 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 ⁇ , for example from> 9 ⁇ to ⁇ example of>
  • 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.
  • 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.
  • 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.
  • PET polyethylene terephthalate
  • 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.
  • the fiber material comprises synthetic fibers
  • 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.
  • 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.
  • 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.
  • the carrier 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.
  • 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.
  • an inorganic, for example mineral, material such as talc as a solid in a matrix 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.
  • 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.
  • the carrier material consists to a large extent of the solid material and the matrix material and the fiber material.
  • 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.
  • a production can be particularly cost-effective and process management can be particularly simple.
  • 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.
  • the support material may optionally have between> 0 wt .-% and ⁇ 11 wt .-% of other additives, such as flow aids, heat stabilizers or UV stabilizers.
  • 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.
  • a carrier is very suitable for printing, in particular with a digital printing method, for example an inkjet printing method.
  • a digital printing method for example an inkjet printing method.
  • such carriers can be easily provided with a high-quality decor, which can allow the production of a high-quality panel.
  • 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.
  • 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.
  • the edge regions of the panel can be structured or profiled to provide in particular detachable connecting elements.
  • 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.
  • 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.
  • elastic materials are advantageous, since such profiles alone can be produced by them, which are particularly easy to handle and stable. In particular, no further materials are necessary to produce the fasteners.
  • the 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.
  • the subject matter of the present invention is furthermore a method for producing a decorated wall or floor panel, comprising the method steps:
  • 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.
  • 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.
  • carrier material particles may be obtainable, for example, by an extrusion process.
  • method step a) comprises the processing of a raw material mixture in an extruder, in particular a twin-screw extruder.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • a carrier can be formed, which has a particularly smooth surface and is therefore particularly suitable for the subsequent application of a decorative layer.
  • this embodiment can manage with a smaller number of scattering heads, which can bring benefits in terms of plant technology.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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).
  • the bands may be formed entirely of polytetrafluoroethylene, or glass fiber reinforced plastic bands or steel bands with a polytetrafluoroethylene coating may be used.
  • a shaping of the carrier material arranged between the belt-like conveying means takes place under the action of temperature or heat.
  • 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.
  • it can fill the receiving space forming between the conveying means and thus form an approximately web-shaped support which can be further treated.
  • pressing means for example, rollers and / or a two-belt press can be used.
  • 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%.
  • 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.
  • 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.
  • a decorative substrate can be applied to at least one subregion of the carrier.
  • a primer can be applied in particular for printing processes as a decorative substrate, for example in a thickness of> ⁇ to ⁇ 60 ⁇ .
  • 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.
  • a white colored primer may be applied.
  • the primer may have polyurethane, be designed as a polyurethane varnish, for example, and be provided with white pigments.
  • the decor it is possible to apply the decor to a decorative paper which can be printed with a corresponding decor, which can be provided as a connection means, for example, by means of a resin layer previously applied to the support.
  • a resin 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.
  • 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.
  • 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.
  • 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.
  • a radiation-curable composition such as, for example, a radiation-curable lacquer, such as an acrylic lacquer, is also applied to form the wear and / or cover layer.
  • the wear layer hard materials such as titanium nitride, titanium carbide, silicon nitride, silicon carbide, boron carbide, tungsten carbide, tantalum carbide, aluminum oxide (corundum), zirconium oxide or mixtures thereof, to increase the wear resistance of the layer.
  • the application can be applied for example by means of rollers, such as rubber rollers or by means of pouring devices.
  • 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.
  • 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.
  • 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
  • a printing substrate 16 is provided, which serves as a substrate for a particular printed decorative layer
  • 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.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Finishing Walls (AREA)
  • Compositions Of Macromolecular Compounds (AREA)
  • Floor Finish (AREA)

Abstract

La présente invention concerne un matériau de substrat destiné à la réalisation d'un substrat (12) pour un panneau mural ou un panneau de sol (10) pourvu d'un décor. Le matériau de substrat (14) comprend un matériau de matrice, un matériau solide et un matériau fibreux. Le matériau solide est composé, en une proportion d'au moins 50% en poids, en particulier d'au moins 80% en poids, voire d'au moins 95% en poids du matériau solide, d'un matériau inorganique, le matériau de matrice est présent en une proportion de ≥ 20% en poids à ≤ 60 % en poids, en particulier de ≥ 28% en poids à ≤ 48% en poids, voire de ≥ 35 % en poids à ≤ 41% en poids du matériau de substrat, et la matériau solide est présent en une proportion de ≥ 25% en poids à ≤ 65 % en poids, en particulier de ≥ 33 % en poids à ≤ 53% en poids, voire de ≥ 40% en poids à ≤ 46 % en poids du matériau de substrat, et le matériau fibreux est présent en une proportion de > 1 % en poids à ≤ 35% en poids, en particulier de ≥ 7% en poids à ≤ 30% en poids, voire de ≥ 14% en poids à ≤ 21% en poids du matériau de substrat, et le matériau de matrice, le matériau fibreux et le matériau solide représentent ensemble une proportion de 89 % en poids, en particulier de ≥ 95% en poids, voire de ≥ 97% en poids du matériau de substrat (20).
EP17801481.7A 2016-11-25 2017-11-24 Matériau de substrat pour panneau mural ou panneau de sol pourvu d'un décor Pending EP3544823A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
EP16200678.7A EP3326835A1 (fr) 2016-11-25 2016-11-25 Substrat pour un panneau de sol ou de mur décoré
PCT/EP2017/080372 WO2018096104A1 (fr) 2016-11-25 2017-11-24 Matériau de substrat pour panneau mural ou panneau de sol pourvu d'un décor

Publications (1)

Publication Number Publication Date
EP3544823A1 true EP3544823A1 (fr) 2019-10-02

Family

ID=57609662

Family Applications (2)

Application Number Title Priority Date Filing Date
EP16200678.7A Withdrawn EP3326835A1 (fr) 2016-11-25 2016-11-25 Substrat pour un panneau de sol ou de mur décoré
EP17801481.7A Pending EP3544823A1 (fr) 2016-11-25 2017-11-24 Matériau de substrat pour panneau mural ou panneau de sol pourvu d'un décor

Family Applications Before (1)

Application Number Title Priority Date Filing Date
EP16200678.7A Withdrawn EP3326835A1 (fr) 2016-11-25 2016-11-25 Substrat pour un panneau de sol ou de mur décoré

Country Status (4)

Country Link
US (1) US11279070B2 (fr)
EP (2) EP3326835A1 (fr)
CN (1) CN110225832A (fr)
WO (1) WO2018096104A1 (fr)

Families Citing this family (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
NL2023587B1 (en) * 2019-07-29 2021-02-18 I4F Licensing Nv Decorative panel and method of producing such a panel
CN112443120B (zh) * 2020-12-15 2021-10-29 安徽森泰木塑科技地板有限公司 一种pvc共挤发泡地板及其制备方法
CN113047563A (zh) * 2021-03-30 2021-06-29 广东蕉岭建筑工程集团有限公司 一种薄层保温地坪的施工方法

Family Cites Families (15)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4540624A (en) 1984-04-09 1985-09-10 Westinghouse Electric Corp. Antistatic laminates containing long carbon fibers
DE19722339A1 (de) * 1997-05-28 1998-12-03 Targor Gmbh Schichtverbundmaterial mit kratzfester Oberfläche, Verfahren zu seiner Herstellung und seine Verwendung
SE516696C2 (sv) * 1999-12-23 2002-02-12 Perstorp Flooring Ab Förfarande för framställning av ytelement vilka innefattar ett övre dekorativt skikt samt ytelement framställda enlit förfarandet
US20060264544A1 (en) * 2005-05-17 2006-11-23 Arnold Lustiger Cloth-like fiber reinforced polypropylene compositions and method of making thereof
US8110132B2 (en) 2008-02-13 2012-02-07 James Hardie Technology Limited Process and machine for manufacturing lap siding and the product made thereby
CA2727491A1 (fr) * 2008-06-10 2009-12-17 Dow Global Technologies Inc. Formation de motifs colores de surface pendant l'etirage d'articles polymeres
EP2700508A1 (fr) * 2012-08-24 2014-02-26 Akzenta Paneele + Profile GmbH Procédé d'impression d'un panneau mural ou de sol
DE102012112556B4 (de) * 2012-12-18 2018-09-27 Isimat Gmbh Siebdruckmaschinen Verfahren und Vorrichtung zum Kaltprägen auf dreidimensionale Gegenstände
EP2829415A1 (fr) 2013-07-22 2015-01-28 Akzenta Paneele + Profile GmbH Procédé de fabrication d'un panneau mural et de sol décoré
EP3323628B1 (fr) 2014-02-25 2022-06-15 Akzenta Paneele + Profile GmbH Procédé de fabrication de panneaux décoratifs
US10329440B2 (en) * 2014-04-15 2019-06-25 Agfa Nv Aqueous resin based inkjet inks
WO2016103470A1 (fr) * 2014-12-26 2016-06-30 ポリプラスチックス株式会社 Composition de résine de sulfure de polyarylène et article moulé sur prisonnier
PT3147135T (pt) * 2015-09-24 2021-02-05 Akzenta Paneele Profile Gmbh Processo para a produção de um painel decorado de parede ou de pavimento
PL3345774T3 (pl) 2017-01-04 2021-06-14 Akzenta Paneele + Profile Gmbh Sposób wytwarzania dekorowanego panelu ściennego lub podłogowego
EP3348418A1 (fr) 2017-01-11 2018-07-18 Akzenta Paneele + Profile GmbH Panneau de sol ou mural à surface structurée et décorée

Also Published As

Publication number Publication date
WO2018096104A1 (fr) 2018-05-31
US20200164561A1 (en) 2020-05-28
EP3326835A1 (fr) 2018-05-30
US11279070B2 (en) 2022-03-22
CN110225832A (zh) 2019-09-10

Similar Documents

Publication Publication Date Title
EP3024669B1 (fr) Procédé de fabrication d'un panneau mural et de sol décoré
EP3578384B1 (fr) Matériau porteur à base d'une composition de matière plastique et d'une composition de matière solide minérales pour panneaux muraux ou de sol décorés
EP3178652B1 (fr) Panneau de decoration et son procede de fabrication
EP3147135B1 (fr) Procede de fabrication d'un panneau mural ou de sol decore
EP3568307B1 (fr) Panneau de sol ou mural à surface structurée et décorée
WO2012136188A1 (fr) Revêtement de sol et procédé de fabrication de ce revêtement
WO2018130401A1 (fr) Panneau mural ou panneau de sol décoratif à surface structurée à base d'une plaque de fibrociment
WO2018096104A1 (fr) Matériau de substrat pour panneau mural ou panneau de sol pourvu d'un décor
EP3837110B1 (fr) Panneau décoratif doté d'une plaque porteuse en matière plastique multilaminaire et son procédé de fabrication
EP3132945B1 (fr) Procede de fabrication d'un panneau mural ou de sol decore
EP3565724B1 (fr) Support à base de matière plastique pour panneau de mur ou de plancher décoré
EP3837112B1 (fr) Plaque support en plastique multilaminaire et son procede de production
EP3088204A1 (fr) Procédé de fabrication d'un panneau mural ou de sol décoré
EP3424706B1 (fr) Composant en forme de plaque et son procédé de fabrication
EP3543034A1 (fr) Plaque porteuse pour un panneau de paroi, de sol ou de plafond directement imprimés
EP3974176B1 (fr) Feuille de protection de fermeture pour panneaux décoratifs
EP3088205A1 (fr) Procédé de fabrication d'un panneau mural ou de sol décoré
EP3536517A1 (fr) Matériau support à base de minéraux pour panneaux muraux ou de plancher décorés

Legal Events

Date Code Title Description
STAA Information on the status of an ep patent application or granted ep patent

Free format text: STATUS: UNKNOWN

STAA Information on the status of an ep patent application or granted ep patent

Free format text: STATUS: THE INTERNATIONAL PUBLICATION HAS BEEN MADE

PUAI Public reference made under article 153(3) epc to a published international application that has entered the european phase

Free format text: ORIGINAL CODE: 0009012

STAA Information on the status of an ep patent application or granted ep patent

Free format text: STATUS: REQUEST FOR EXAMINATION WAS MADE

17P Request for examination filed

Effective date: 20190429

AK Designated contracting states

Kind code of ref document: A1

Designated state(s): AL AT BE BG CH CY CZ DE DK EE ES FI FR GB GR HR HU IE IS IT LI LT LU LV MC MK MT NL NO PL PT RO RS SE SI SK SM TR

AX Request for extension of the european patent

Extension state: BA ME

DAV Request for validation of the european patent (deleted)
DAX Request for extension of the european patent (deleted)
STAA Information on the status of an ep patent application or granted ep patent

Free format text: STATUS: EXAMINATION IS IN PROGRESS

17Q First examination report despatched

Effective date: 20210715

STAA Information on the status of an ep patent application or granted ep patent

Free format text: STATUS: EXAMINATION IS IN PROGRESS

P01 Opt-out of the competence of the unified patent court (upc) registered

Effective date: 20230526