EP3990719A1 - Élément de construction en forme de plaque et son procédé de fabrication - Google Patents

Élément de construction en forme de plaque et son procédé de fabrication

Info

Publication number
EP3990719A1
EP3990719A1 EP20725074.7A EP20725074A EP3990719A1 EP 3990719 A1 EP3990719 A1 EP 3990719A1 EP 20725074 A EP20725074 A EP 20725074A EP 3990719 A1 EP3990719 A1 EP 3990719A1
Authority
EP
European Patent Office
Prior art keywords
layer
carrier plate
component according
wear layer
wood
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
EP20725074.7A
Other languages
German (de)
English (en)
Inventor
Guido Schulte
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.)
SCHULTE, GUIDO
Original Assignee
Individual
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 Individual filed Critical Individual
Publication of EP3990719A1 publication Critical patent/EP3990719A1/fr
Pending legal-status Critical Current

Links

Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/02—Flooring or floor layers composed of a number of similar elements
    • E04F15/10—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials
    • E04F15/102—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials of fibrous or chipped materials, e.g. bonded with synthetic resins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B1/00—Producing shaped prefabricated articles from the material
    • B28B1/52—Producing shaped prefabricated articles from the material specially adapted for producing articles from mixtures containing fibres, e.g. asbestos cement
    • B28B1/525—Producing shaped prefabricated articles from the material specially adapted for producing articles from mixtures containing fibres, e.g. asbestos cement containing organic fibres, e.g. wood fibres
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/02—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/02—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
    • C04B28/10—Lime cements or magnesium oxide cements
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/14—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing calcium sulfate cements
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/30—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing magnesium cements or similar cements
    • C04B28/32—Magnesium oxychloride cements, e.g. Sorel cement
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/02—Flooring or floor layers composed of a number of similar elements
    • E04F15/02038—Flooring or floor layers composed of a number of similar elements characterised by tongue and groove connections between neighbouring flooring elements
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/02—Flooring or floor layers composed of a number of similar elements
    • E04F15/10—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
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
    • C04B2111/00612—Uses not provided for elsewhere in C04B2111/00 as one or more layers of a layered structure
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/60—Flooring materials
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F2201/00—Joining sheets or plates or panels
    • E04F2201/01—Joining sheets, plates or panels with edges in abutting relationship
    • E04F2201/0153—Joining sheets, plates or panels with edges in abutting relationship by rotating the sheets, plates or panels around an axis which is parallel to the abutting edges, possibly combined with a sliding movement
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
    • Y02W30/00—Technologies for solid waste management
    • Y02W30/50—Reuse, recycling or recovery technologies
    • Y02W30/91—Use of waste materials as fillers for mortars or concrete

Definitions

  • the invention relates to a plate-shaped component, in particular a floor panel and a method for its production.
  • Surface coverings for example floor coverings, come in a wide variety of designs.
  • Panel-shaped structural elements are widespread, in particular floor panels in the form of laminate or parquet with carrier panels made of compacted fiber materials.
  • On the upper side of the carrier plate there is usually a multi-layered wear layer.
  • This has a decorative layer, for example a resin-coated decorative paper.
  • the decorative layer determines the look of the laminate.
  • the so-called overlay forms a seal as the top layer and gives the component a high level of surface resistance.
  • a counter tension can be applied to the underside of the carrier plate. This is used for dimensional stability and moisture barrier. If necessary, impact sound insulation can also be provided on the underside.
  • click system In order to connect the components to one another, these are mostly provided with a so-called click system.
  • These are mechanical locking means on the grooves and on the tongues, which come into locking engagement with one another in the case of adjacent components in a floor covering. This is intended to avoid the formation of joints in the installed floor covering
  • DE 10 2013 113 478 A1 discloses a plate-shaped component in the form of a panel, which has a carrier plate and a top-side wear layer.
  • the carrier plate consists of a composite material made of fibers and a hydraulic binder.
  • the wear layer consists of a plastic reinforced with natural materials. The carrier plate and the wear layer are hot-pressed together.
  • a floor panel is also known from DE 10 2005 017 392 A1 which has a carrier plate, a wear layer with a decorative layer and an overlay being arranged above the carrier plate.
  • the carrier plate is formed on the basis of a mineral material and a binding agent.
  • the previously explained three-layer structure of a plate-shaped component with profiled joining surfaces is common, the carrier plate consisting of a compacted fiber board.
  • the fiber boards are basically well suited for the purpose. They have the necessary stability, are easy to process and inexpensive. Nevertheless, with regard to the properties of use, in particular the resistance to moisture, weathering and fungal attack by fungal and / or Pest infestation, for example by termites, but also with regard to sustainability, potential for improvement.
  • the invention is based on the object of creating an advantageous, qualitatively improved, plate-shaped component with advantageous properties of use and of indicating a method for its production.
  • a method according to the invention is characterized in claim 15.
  • the plate-shaped component has a carrier plate and a top-side wear layer.
  • the carrier plate is formed on the basis of a wood material and / or a plant material and magnesium oxide (MaO).
  • MoO magnesium oxide
  • the proportion of the wood-based material and / or the vegetable material in the carrier board is at least 65% and the proportion of magnesium oxide is at least 5%. It is also essential to the invention that the carrier plate and the wear layer are pressed together under the action of temperature and pressure.
  • the carrier plate is formed on the basis of a wood material and / or a plant material and magnesium oxide.
  • the proportion of wood-based material and / or plant material is at least 65%.
  • Wood-based materials are materials that consist of shredded wood, plant materials consist of shredded plants.
  • the wood particles and / or plant particles can be in the form of chips, fibers and / or powder.
  • bamboo in particular is used as a plant material.
  • An essential aspect of the invention is that the carrier plate consists at least for the most part of renewable, in particular rapidly renewable, raw materials.
  • Magnesium oxide is a binding agent and causes the carrier plates to become waterproof or highly water-resistant despite the comparatively high proportion of wood-based and / or plant-based material.
  • the invention realizes an optimum between the highest possible proportion of fiber material from renewable raw materials and the binding agent magnesium oxide.
  • the combination of the mineral binder magnesium oxide with the wood-based materials / vegetable materials in chip, fiber or powder form in the mixing ratios shown according to the invention allow the production of a high-quality panel-shaped component according to the invention.
  • the component according to the invention has an edge swelling of significantly less than 5%, and depending on the formulation, even less than 2%.
  • the product is flame retardant or, depending on the surface, also classified as non-combustible class A2.
  • the plate-shaped component according to the invention shows a significantly higher elasticity and compared to known magnesium plates Deformability. This is particularly important for floor coverings with a thickness of 4 mm to 10 mm, especially if they are laid floating on a footfall sound insulation underlay.
  • the technological and ecological properties are optimally combined in the panel-shaped component according to the invention.
  • the carrier board is slightly compressible and thus corresponds in many properties to a wood fiber board, but is flame retardant, non-combustible and does not swell.
  • the panel-shaped component also absorbs only a little moisture.
  • the proportion of wood-based material and / or the proportion of plant material in the carrier plate is particularly preferably at least 75%.
  • the proportion of wood material and / or plant material in the carrier plate is at least 85%.
  • a mixture of wood-based material and vegetable material can also form the basis of the carrier plate, the sum of wood-based material and vegetable material being in the range specified according to the invention.
  • the magnesium oxide is the determining binder in the base of the carrier plate. This is mixed with the wood-based materials and / or plant-based materials and pressed to form the carrier plate. Despite the high wood material or fiber material of more than 65%, the carrier plate does not swell, but is nevertheless elastic to a limited extent. The high proportion of wood or plant materials results in a surface that is suitable for direct pressing with layers containing adhesive components, in particular melamine resins or impregnated papers.
  • the carrier board can contain further additives, for example fillers. Hydraulic binders in particular are additives.
  • magnesium chloride is also particularly preferred (MgCl2) and / or calcium sulfate dihydrate (gypsum) (CaS04 2 H20) or cement, for example lime cement.
  • One aspect of the invention provides for the pressing of the carrier plate and the wear layer in a short-cycle press or a continuous press.
  • the layers and the layers forming the layers are pressed together under heat and pressure.
  • the pressure build-up and pressure reduction of the press can be regulated in stages.
  • the components that is to say the carrier plate or a large-area initial carrier plate and the components of the wear layer, are arranged in the press on the press table.
  • the press is closed and the temperature and pressure act on the components.
  • the wear layer has adhesive components. These are temperature-activated adhesive components. During hot pressing, the adhesive components and possibly other binder components are activated and plasticized.
  • Adhesive components in the wear layer are resins, especially polycondensation resins.
  • Melamine- or polyurethane-based adhesive components are preferably used. These can be built into the wear layer separately, for example as a powder layer.
  • the adhesive components are particularly expediently integrated in a layer of the wear layer, for example melamine or polyurethane-impregnated decorative papers are used.
  • Carrier plate and wear layer connect with one another. The surface and the structure of the component are shaped. The adhesive or resin components cure immediately upon cooling.
  • the adhesives are formulated in such a way that they bind when they cool down, but still have elastic properties.
  • the adhesives in the form of resins are preferably elasticized by adding polyurethane.
  • the wood and / or vegetable materials of the carrier board in the proportions specified according to the invention bring about a layer-appropriate absorption capacity for the binder and, if necessary, additional resins and support their migration, wetting and binding capacity.
  • the system forming the carrier plate is coordinated in such a way that an optimized adhesive bond between the components is achieved after the binding agent has set and the complete reaction and any resins.
  • the components themselves, their proportion and also their grain size and moisture content are optimized according to the layer and coordinated in such a way that dehesive surface tension and influences that impair adhesion, for example water vapor, are minimized or evened out.
  • the wear layer can be a single layer of decorative paper.
  • the decorative paper is a cellulose-based layer of paper that has a decorative surface.
  • the decorative paper is impregnated with adhesive components, for example curable synthetic resin. This is preferably an aminoplastic resin, a melamine resin, a polyurethane or a mixture of the aforementioned substances.
  • the weight fraction of the impregnation is 70 to 130 percent by weight, based on the weight of the starting paper.
  • the impregnation can contain additives, for example antistatic agents or additives that increase wear resistance.
  • the invention provides in particular that the wear layer and the carrier plate are pressed directly with one another.
  • the wear layer has at least one adhesive layer.
  • the layer can consist of adhesive components or contain adhesive components. If the wear layer only comprises one layer of decorative paper, this is pressed directly onto the carrier plate.
  • the wear layer can be at least one layer made of paper, in particular made of melamine or polyurethane-impregnated decorative paper, fabric, decorative laminate, dye, sealing material, wear protection, fleece, vinyl, wood veneer, cork, polyethylene terephthalate (PET), polyethylene (PE) or polypropylene (PP) exhibit.
  • the wear layer is preferably constructed in several layers. Multiple layers of paper or coated film can be provided. Furthermore, one or more layers of core paper can be integrated below the layer of decorative paper.
  • the wear layer can furthermore comprise an overlay (protective layer) which is arranged above the decorative paper.
  • the overlay that is to say the protective layer, preferably contains abrasion-resistant components, in particular minerals, preferably corundum particles. These highly abrasion-resistant components are already added during the impregnation of the overlay.
  • the wear layer has a decor-imparting decor layer, in particular a resin-impregnated decor paper or a printed decor layer, as well as a wear protection layer arranged on the top.
  • the decorative paper can also be impregnated with abrasion-resistant components, e.g. Corundum or silanized corundum can be applied.
  • abrasion-resistant components e.g. Corundum or silanized corundum can be applied.
  • Corundum or silanized corundum can be applied.
  • the wear layer is reinforced by at least one reinforcement layer. This can improve the tear resistance of the wear layer and in particular of the decorative paper contained in the wear layer.
  • Nonwovens, glass fabrics or glass fleeces are used as reinforcement layers.
  • the at least one reinforcement layer is arranged below the decorative paper.
  • the reinforcement layer is also preferably resin-impregnated.
  • a stabilization layer can be integrated into the carrier plate. This can be a prefabricated stabilization layer that is inserted into the Carrier plate is embedded in their manufacture. In particular, nonwovens, mesh or fabric layers are used as stabilization layers.
  • a carrier plate with a density of greater than or equal to (>) 700 kg / m 3 is advantageous.
  • the carrier plate has a density between greater than or equal to (>) 700 kg / m 3 and greater than or equal to (>) 1,800 kg / m 3 .
  • Particularly preferred is a carrier plate whose density is between 900 kg / m 3 and 1,400 kg / m 3 inclusive.
  • a carrier plate with a transverse tensile strength of greater than or equal to (>) 1.5 N / m 2 is also advantageous, in particular the carrier plate has a transverse tensile strength between 2.0 N / m 2 and 6.0 N / m 2 .
  • the wear layer can be ground flat. Depending on the surface requirements, an abrasive with a grain size of 80 or 120 can be used.
  • the surface of the carrier plate facing the wear layer can alternatively be provided with a surface-enlarging profile.
  • the surface-enlarging profiling takes place in particular by mechanical means, preferably by roughening. This can be done by grinding, brushing and / or embossing. Roughening the carrier plate increases its surface. The macroscopic conditions of the surface have an influence on the bond strength. As the surface area increases after roughening, the surface-dependent atomic and molecular interactions increase. This improves the adhesion between the carrier plate and the wear layer.
  • the mechanical processing of the surface of the carrier plate can also be useful in order to level out unevenness in the plate or layer.
  • the carrier plate surface can be provided with a structure in this way. In addition to grinding, such a structure can also be created by milling, brushing or embossing. These with an excepted structure on the surface
  • the carrier plate provided is pressed with the wear layer. This makes it possible to obtain structures on the surface, ie on the visible side of the component, which are deeper than the actual thickness of the wear layer.
  • the surface of the carrier plate can be subjected to a profile-giving surface treatment in such a way that the structure can be seen in the finished component surface.
  • the structures can be, for example, serrated structures or joint-like depressions. This enables the reproduction of stone or tile decors.
  • the surface of the carrier plate is provided with a structure or a structure image which can be seen on the visible side of the finished plate-shaped component and gives it the surface appearance.
  • the structuring takes place in particular through mechanical processing.
  • the panel-shaped component according to the invention is in particular a floor panel.
  • the plate-shaped component has a top side, a bottom side and at least four edge sides.
  • the edge sides are designed to be connected to the edge sides of further plate-shaped components in order to cover an area of a room.
  • connecting means are formed on the side edges of the carrier plate, for example in the form of tongue and groove or latching and / or click connections.
  • the carrier plate is provided with a seal at least on the underside.
  • the seal serves in particular to block off moisture and / or supports the resistance of the carrier plate to moisture, weathering and / or fungal attack.
  • such a carrier plate is waterproof.
  • the panel-shaped components according to the invention are suitable for damp rooms.
  • the carrier plate is provided with a seal or a sealant at the top and bottom as well as on the side edges or edge surfaces. Due to the binder in the carrier board, it shows almost no swelling behavior.
  • a counter-tension is preferably provided on the underside of the carrier plate. This serves as stabilization and can act as impact sound insulation.
  • the backing can be applied separately. It is possible and advantageous to apply the counter tension when pressing the carrier plate and the wear layer, that is, the counter tension layer is pressed together with the carrier plate and wear layer.
  • the balancing sheet preferably consists of an impregnated fleece or fabric layer. These have tensile properties tailored to the finished component.
  • a large-format starting carrier plate with a rectangular configuration is provided.
  • Large-format means that the initial carrier plate has dimensions that are many times larger than the plate-shaped component to be produced.
  • the output carrier plate can, for example, have a width of 1,220 mm and a length of 2,440 mm.
  • the starting carrier plate is formed on the basis of a wood material and / or a plant material as well as magnesium oxide.
  • the wood-based material and / or the plant-based material make up the major share of at least 65% in total.
  • the proportion of magnesium oxide is at least 5%.
  • the initial carrier plate is not yet profiled at the edge, that is, the side edges do not yet have any connecting means.
  • the wear layer is arranged on the initial carrier plate.
  • the wear layer can be constructed in one layer, but in particular in multiple layers.
  • the wear layer has at least one adhesive layer.
  • the wear layer preferably comprises at least one melamine or polyurethane impregnated decorative paper and an overlay arranged thereon.
  • the overlay forms a transparent one Wear layer and can also consist of impregnated paper. It is also possible to apply the overlay as a pasty or liquid coating.
  • the carrier plate and the wear layer are then pressed together under the action of temperature and pressure, and thereby connected.
  • the multi-layer body is pressed in a hot press.
  • the components of the multilayer body are positioned in the press.
  • the pressing takes place at temperatures in a range from 100 ° Celsius to 240 ° Celsius. This temperature is set on the surface of a press plate that is brought into contact with the component.
  • the temperature effect takes place from the side of the wear layer, that is to say from the top. In particular, this is preferably done when the counter-pull is applied later in a further separate operation.
  • the pressing temperature is in particular above 120 ° C.
  • the temperature is preferably between 180 ° C. and 210 ° C. inclusive.
  • the pressing time is in particular less than or equal to ( ⁇ ) 120 seconds.
  • the pressing time is between 5 seconds and 60 seconds, preferably between 5 seconds and 45 seconds.
  • the pressing pressure is greater than or equal to (>) 1,000 kilopascals (kPa) and can be up to and including 6,500 kPa.
  • the pressing pressure is preferably greater than or equal to (>) 3,500 kPa.
  • a short-cycle press or a continuous press are used as the press.
  • An adhesion promoter can be provided between the carrier plate and the wear layer.
  • the adhesion promoter improves the adhesion between the wear layer and the carrier plate.
  • the adhesion promoter is preferably used separately as part of a surface treatment of the carrier plate or the Output carrier plate applied. Modified polyolefins or also silane adhesion promoters are suitable as adhesion promoters. Polyurethane undercoats or primers are also suitable.
  • An adhesion promoter that is advantageous for practical use is a PUR binder, which hardens by absorbing moisture from the ambient air or the starting carrier plate.
  • Moisture from the pressing process can escape into the carrier plate.
  • the surface of the wear layer can be given a structure, a pattern or ornaments by means of a structured sheet or a structure generator.
  • the structure can vary in the degree of gloss in some areas. Furthermore, different structure depths are possible.
  • the pressed multi-layer body is removed from the press. Immediately or later on, the pressed multi-layer body is separated or divided into individual plate-shaped components. The individual components are profiled on their side edges in a subsequent work step. Profiling takes place after the pressed multi-layer body has cooled down at room temperature. When profiling, the individual components are provided with connecting means on their side edges, i.e. on the long and narrow sides.
  • the plate-shaped component can have a total thickness between 4 mm and 20 mm.
  • the wear layer can have a structure that fits synchronously with the decor image.
  • the surface of the finished component can have different degrees of gloss, preferably 3 to 4 different degrees of gloss, matching or coordinated with the decorative image of the decorative paper.
  • the wear layer has a thickness in a range from 0.10 to 0.50 mm.
  • the wear layer preferably has a protective layer above the decorative layer. This preferably contains anti-abrasive components.
  • the protective layer which is also referred to as an overlay, can be a layer made of impregnated noble cellulose. This becomes transparent during pressing.
  • the protective layer can alternatively also be applied to the decorative layer as a liquid layer or as a powder and connects to the decorative layer during pressing.
  • the purpose of the protective layer is to protect the decor against abrasion, scratches and other damage.
  • aminoplastic resins in particular melamine resins or polyurethane-based resins
  • the resins After curing through polycondensation, the resins form thermosetting plastics.
  • the carrier plate and the wear layer are pressed together to form the panel-shaped component immediately under the influence of temperature and heat.
  • a lubricant and / or sealant can be applied to the side edges of the carrier plate.
  • the side edges of the carrier plate can be provided with a water repellent, the water repellent containing antimicrobial and / or antibacterial agents.
  • the plate-shaped component according to the invention is waterproof.
  • the construction element absorbs a maximum of 5% water and does not tend to swell, as is the case with conventional wood-based construction elements or panel materials.
  • the edge swelling is less than 3% after 24 hours of immersion in water.
  • the component according to the invention can be flame retardant, classified as non-flammable and non-swelling.
  • the panel-shaped construction element shows a slight increase in length and width and is therefore very dimensionally stable and can be installed floating over distances of more than 15 meters without movement joints.
  • a component according to the invention has a high level of resistance to moisture, weathering and fungal attack. In addition, it consists largely of renewable raw materials. This is a particularly advantageous aspect in terms of the usage properties.
  • Figure 1 is a side view of an inventive plate-shaped component
  • FIG. 2 shows a section from the connection area of two components connected to one another.
  • FIGS 1 and 2 are technically schematic and should not be understood to be true to scale.
  • FIG. 1 shows a plate-shaped component 1 in the form of a floor panel.
  • FIG. 2 shows a section of two components 1 connected to one another.
  • the component 1 is configured in a rectangular manner and has a carrier plate 2 with a wear layer 3 on the top.
  • a counter-tension layer 4 is provided on the underside of the carrier plate 2 and is glued over the entire surface to the underside of the carrier plate 2.
  • the counter-tension layer 4 supports the dimensional stability of the component 1 and serves to block moisture and to insulate footfall sound.
  • the carrier plate 2 is formed on the basis of a wood material and / or a plant material and magnesium oxide (MaO).
  • the proportion of wood-based material and / or of the plant-based material in the carrier plate 2 is at least 65%, preferably the proportion of wood-based material and / or at least 75% of plant material in the carrier plate.
  • a carrier plate 2 which has a wood material content and / or a plant material content of at least 85% is particularly advantageous.
  • the proportion of magnesium oxide in the carrier plate is at least 5%.
  • a mixture of wood material and plant material can also be used.
  • the wood and / or plant material particles are in the form of chips, fibers and / or powder. These are mixed with the magnesium oxide and pressed or connected in the form of plates.
  • other binders can be included. These are in particular hydraulic binders.
  • the upper wear layer 3 is constructed in one or more layers. In the embodiment shown here, two layers 5, 6 are shown.
  • a layer 5 of the wear layer 3 is adhesive, that is, the layer consists of adhesive components or contains adhesive components.
  • the adhesive layer 5 is, in particular, a melamine or polyurethane-impregnated decorative paper.
  • the adhesive layer 5 can also be a layer made of a resin-coated or resin-impregnated real wood veneer.
  • the top layer 6 is an overlay. This forms a seal and gives the panel-shaped structural element 1 a high degree of surface durability. Corundum particles are contained in layer 6, which increases the microscratch and wear resistance.
  • the upper layer 6 on the step side forms a wear protection layer.
  • the plate-shaped component 1 is profiled on its side edges 7, 8 and provided with connecting means 9 and 10.
  • the connecting means 9 on the first side edge 7 has a continuous coupling groove 11 and a locking tongue 12 protruding on the bottom.
  • a continuous, nose-like rib 13 is formed at the free end of the locking tongue 12.
  • the locking means 10 is formed by a protruding coupling spring 14.
  • a latching groove 15 is provided on the underside of the clutch spring 14.
  • the coupling groove 11 and the clutch springs 14 are matched to one another in terms of their contour in such a way that when the structural elements 1 are laid they come into locking engagement with one another when the structural elements 1 are adjacent in a floor covering.
  • a multilayer body is formed.
  • a large-area starting carrier plate is provided, which is formed on the basis of a wood material and / or a plant material as well as magnesium oxide.
  • the proportion of wood-based material and / or the proportion of vegetable material total at least 65%.
  • the proportion of magnesium oxide is at least 5%.
  • a wear layer which has at least one adhesive layer 5, is applied to the top of the output carrier plate.
  • a counter-tension layer 4 is arranged on the underside of the output carrier plate.
  • the multilayer body is then hot-pressed in a press.
  • the wear layer 3 is firmly connected to the output carrier plate, and the counter-tension layer 4 is also firmly connected to the output carrier plate.
  • the adhesive is plasticized in the adhesive layer.
  • the wear layer 3 is pressed and glued to the initial carrier plate. The same applies to counter-pull position 4.
  • the pressing pressure is more than 1000 kilopascals (kPa), preferably the pressing pressure is greater than or equal to (>) 3,500 kilopascals (kPa).
  • the pressing temperature is above 100 ° C, in particular the pressing temperature is greater than or equal to (>) 120 ° C.
  • the pressing temperature is preferably between 180 ° C and 210 ° C.
  • the pressing time is less than 2 minutes (120 seconds). In particular, the pressing time is between 5 and 60 seconds, advantageously between 10 and 45 seconds.
  • the pressed multi-layer body is removed from the press and, after cooling, is separated into individual plate-shaped components 1.
  • the components 1 are profiled at their side edges 7, 8 and provided with the connecting means 9, 10.
  • the initial carrier plate can be sealed prior to the formation of the multilayer body.
  • the starting carrier plate can be coated with a seal on the underside or a seal can be applied to the underside.
  • a structure When pressing the multilayer body, a structure can be pressed into the surface of the wear layer.
  • a lubricant and / or sealant can be applied to the side edges 7, 8 of the carrier plate 2 on the finished components 1. Furthermore, the side edges 7, 8 of the components 1 can be provided with a water repellent, the water repellent containing in particular antimicrobial and / or antibacterial agents.
  • the side edges 7, 8 of the carrier plate 2 or of the plate-shaped component 1 can be quenched by a bevel on all four or only on two edges.
  • the bevel can be colored in contrast or to match the decor.
  • the bevels can be lacquered or transparent.

Abstract

L'invention concerne un élément de construction (1) en forme de plaque, en particulier un panneau de sol, et un procédé de fabrication de cet élément. Les bords latéraux (7, 8) de cet élément de construction (1) en forme de plaque sont conçus pour être assemblés avec d'autres éléments de construction (1) afin de recouvrir une surface d'une pièce. L'élément de construction (1) présente une plaque de support (2) et une couche d'usure (3) supérieure. La plaque de support (2) est formée à base d'un matériau dérivé du bois et/ou d'un matériau dérivé de plantes et à base d'oxyde de magnésium (MaO). La proportion de matériau dérivé du bois et/ou de matériau dérivé de plantes est d'au moins 65 % et la proportion d'oxyde de magnésium est d'au moins 5 %. La plaque de support (2) et la couche d'usure (3) sont comprimées ensemble sous l'action de la température et de la pression.
EP20725074.7A 2019-06-27 2020-04-28 Élément de construction en forme de plaque et son procédé de fabrication Pending EP3990719A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102019117425.2A DE102019117425A1 (de) 2019-06-27 2019-06-27 Plattenförmiges Bauelement und Verfahren zu dessen Herstellung
PCT/DE2020/100345 WO2020259736A1 (fr) 2019-06-27 2020-04-28 Élément de construction en forme de plaque et son procédé de fabrication

Publications (1)

Publication Number Publication Date
EP3990719A1 true EP3990719A1 (fr) 2022-05-04

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EP20725074.7A Pending EP3990719A1 (fr) 2019-06-27 2020-04-28 Élément de construction en forme de plaque et son procédé de fabrication

Country Status (3)

Country Link
EP (1) EP3990719A1 (fr)
DE (1) DE102019117425A1 (fr)
WO (1) WO2020259736A1 (fr)

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
NL2025684B1 (en) * 2020-05-26 2021-12-14 Champion Link Int Corp Panel and method for producing a panel
US11724537B2 (en) * 2020-05-26 2023-08-15 Champion Link International Corporation Panel and method for producing a panel

Family Cites Families (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102005017392A1 (de) * 2005-04-14 2006-10-19 Witex Ag Fußbodenbelag
DE102012000468B4 (de) * 2012-01-13 2017-08-17 Falquon Gmbh Bodenpaneel und Verfahren zu seiner Herstellung
DE102013113130B4 (de) * 2013-11-27 2022-01-27 Välinge Innovation AB Verfahren zur Herstellung einer Fußbodendiele
DE102013113478A1 (de) * 2013-12-04 2015-06-11 Guido Schulte Fußboden-, Wand- oder Deckenpaneel und Verfahren zu dessen Herstellung
EP2955295B1 (fr) * 2014-06-12 2018-02-28 Flooring Technologies Ltd. Procédé de fabrication d'un panneau
NL2019108B1 (en) * 2017-06-22 2019-01-07 Champion Link Int Corp Floor panel and method of producing such a floor panel

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DE102019117425A1 (de) 2020-12-31
WO2020259736A1 (fr) 2020-12-30

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