PT106466A - WATERPROOF LAMINATED PANEL WITH A STRUCTURAL LAYER OF CORK BASED MATERIAL AND ITS MANUFACTURING PROCESS - Google Patents

Abstract

(1), a layer (2) of polymeric material disposed on one side of the laminate (1), a layer (3) of a top layer of polyester material disposed on the other side (1) and a continuous layer of polymeric material (4) disposed in the cross-sectional profile on the entire periphery of the panel. The panel of the invention may further comprise a printed film (5) disposed on the top layer (3) and a transparent (6) layer of wear on the printed film (5). The present panel is particularly suitable for use in the construction of flooring. The invention further relates to a panel manufacturing process.

Description

WOODWORKING LAMINATED PANEL WITH A STRUCTURAL LAYER OF CORK BASED MATERIAL AND ITS MANUFACTURING PROCESS "

FIELD OF THE INVENTION The present invention relates to an impermeable laminated panel having a structural layer of cork-based material as well as to its manufacturing process. The present invention applies, without being limited, to decks.

BACKGROUND OF THE INVENTION The use of cork in a variety of industrial applications and more particularly in floors, walls and ceilings is well known.

The natural characteristics of the cork material have been extensively exploited in the production of floors with exceptional characteristics in terms of impact cushioning of steps, as well as acoustic and thermal insulation, among others.

These characteristics of flooring that use cork materials provide high levels of comfort to its users, and the combination of cork with other materials also allows a greater versatility to these products, namely, with regard to aesthetic and other aspects 1 such as wear resistance.

However, given the known permeability to liquids, especially water, cork-based flooring has found no reliable application in places subject to high levels of humidity and / or frequent contact with water and aqueous solutions, such as in kitchens, bathrooms, saunas, swimming pool facilities and the like. Indeed, given the nature of the activities occurring in these places, in addition to the intrinsically wet atmospheres, frequent washing operations are required, which are incompatible with the use of the cork material, which, as mentioned, does not present adequate resistance to wet media. The technique has developed cork-based products that present a combination of materials to overcome this problem, namely through products in " sandwich ", in which the cork layer is coated with layers of impermeable materials. However, these solutions have not proved to be sufficiently reliable, mainly due to the infiltration of liquids in the joining areas between panels or in the areas connecting to the walls of the site, which are the weaknesses from the point of view of total waterproofing of a floor.

These deficiencies or difficulties in the total waterproofing of cork flooring provide, in the course of normal use of such wet spaces, more or less localized areas of soil degradation, as well as concentration of microorganisms, with the corresponding consequences 2 having a harmful impact in the salubrity of spaces and in aesthetic or even structural aspects.

For these reasons, it has not hitherto been possible to provide such wet spaces, in particular kitchens and bathrooms, with cork flooring so as to benefit from their advantages in terms of comfort and thermal insulation and acoustic. European patent EP 1634696 BI discloses a multi-layer flooring element comprising a core layer and a cover layer which is arranged above the core layer. The core layer contains a pressure resistant wood material and the coating layer contains polyvinyl chloride of heterogeneous structure which comprises a foam core and is disposed between two or more sheets. Below the core layer is a layer of cork having a thickness between 1.0 and 3.0 mm. European patent EP 528194 B1 relates to a process for the production of floorings from ethylene-vinyl acetate copolymers and fillers with a transparent cover without polyvinyl chloride (PVC). The linear low density and / or very low density ethylene copolymer containing up to 2% by weight of conventional processing aids is melted and unwound on a calender to obtain a sheet. Such sheet is then duplicated or tripliced with the PVC-free floor sheets based on the ethylene-vinyl acetate copolymer and, optionally, provided with a cloth, fabric or non-woven base support, or cork. A Japanese patent application JP 9151596 discloses a laminate flooring comprising a layer of vinyl chloride resin and wood powder, an adhesive, a layer of cork and a transparent surface layer. The cork layer is formed by natural cork or compressed cork and has a thickness of 0.3-3 mm. German patent application DE 102007008062 discloses a process for the production of floor tiles with digital cork printing. This application further claims the tile, manufactured by said process, comprising: an insulation layer, a layer of HDF, high density cork (thickness 2 to 5 mm), an acrylic based paint, a layer of curing varnish UV and two to four layers of sealant.

While the foregoing documents disclose flooring elements comprising laminated combinations of cork material and thermoplastics, they fail to solve the problems related to the aforementioned liquid infiltration and therefore can not be reliably applied in humid and or subjected to frequent washing operations.

In accordance with the above, there is a need for a laminated panel of cork-based material, fully waterproofed, to install a waterproof floor in wet spaces, allowing the combination of the demanding actions of use and maintenance / cleaning of these spaces with the characteristics of comfort and thermal / acoustic insulation provided by a cork-based floor. 4

There is also a need for an industrial process for producing said impermeable panels, which is technically and economically feasible.

SUMMARY OF THE INVENTION The present invention relates to a laminated panel having a periphery and a transverse profile (P) defined along the entire periphery, the panel comprising: a structural layer (1) of cork-based material, • a base layer (2) of polymeric material disposed on one face of the structural layer (1) and • a top layer (3) of polymeric material disposed on the other face of the structural layer (1), further comprising a layer 4) of continuous seal coating of polymeric material disposed throughout said transverse profile (P).

Preferably, said structural layer (1) is a composite of cork and polymer, namely, a composite of cork and polyvinyl chloride (PVC).

In one aspect of the invention, both the base layer (2) and the top layer (3) are made of PVC.

In one embodiment of the invention, the structural layer (1) has a thickness in the range of 15 to 5 mm, wherein the base layer (2) and the top layer (3) each have a thickness in the range of 0.4 to 2 mm.

Preferably, the panel of the invention comprises a structural layer (1) of a 3 mm thick PVC and cork composite, a 1.2 mm thick PVC base layer (2) and a layer (3) ) PVC top with 1.8 mm thickness.

In a preferred embodiment, the panel further comprises a printed film 5 disposed on the top layer 3 and a transparent wear layer 6 disposed on the printed film 5, wherein the film 5, printed paper has a thickness of up to 0.1 mm and the wear layer (6) has a thickness in the range of 0.2 to 1 mm.

Most preferably, said layers (1, 2, 3, 5, 6) are glued together. The present invention further relates to a process for producing laminated panels defined above, comprising the steps of: a) arranging a network (7) of polymeric material on a base layer (2) of polymeric material, the network ( 7) a certain thickness (E) and the net (7) being formed by at least two adjacent meshes (8), each net (8) defining an empty space (9) and a surrounding edge (10) adjacent meshes (8) connected by a common margin (11) defining a plurality of cutting lines (L); (B) integrally filling the empty space (9) defined by each of said meshes (8) with a respective structural layer (1) of cork-based material; c) disposing a top layer (3) of polymeric material on the assembly formed in step b); d) separating the meshes 8 from the net 7 by cutting into one of the cut lines L of the common margin 11 between adjacent meshes 8, forming as many panels as the meshes 8 of the net 7, , wherein the thickness of the structural layer (1) of cork-based material is equal to the thickness (E) of the network (7) of polymeric material and the layers (1, 2, 3) are inseparably joined together.

Preferably, said net (7) is made of PVC and has a thickness (E) in the range of 1 to 5 mm.

In one aspect of the invention, the structural layer (1) to be used in step b) is a composite of cork and PVC.

In yet another aspect, the base (2) and top layers (3) are made of PVC, each having a thickness in the range of 0.4 to 2 mm.

In a preferred embodiment, the process of the invention further comprises, between said steps c) and d), an additional step 7 of arranging a film 5 printed on the top layer 3 followed by the arrangement of a layer 6) of transparent wear on the printed film (5).

Preferably, the layers (1, 2, 3, 5, 6) are inseparably bonded by gluing and the cutting of step d) is effected by slitting the average line (M) of the common knit margin (11) (8). The invention further relates to a floor formed by the panels as described above.

BRIEF DESCRIPTION OF THE DRAWINGS The following is a description of the invention with reference to the accompanying drawings, in which: Fig. 1 is a schematic perspective view of a panel of the invention showing its cross-section and omitting the coating layer of profile. 2 is a schematic perspective view of the panel of Fig. 1 with the profile facing layer. Fig. Fig. 3 is a schematic perspective view of a preferred embodiment of the invention, with the profile coating layer partially removed to allow visualization of the remaining layers forming the panel. Fig. 4 is a schematic plan view of a floor constructed from panels of the invention showing the joining zones between panels. 5 is a schematic perspective view of an exemplary polymer network used in the panel production process of the invention. Fig. 6 is a schematic perspective view of only one mesh of the network shown in Fig. 5; Fig. 7 is a schematic perspective view of a two-mesh polymer network. 8 is an exploded schematic view illustrating the sequence of steps a), b) and c) of the process of the present invention.

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a laminated panel comprising a structural layer of cork-based material for forming a fully impermeable floor that can be used in wet spaces while ensuring exceptional features in terms of comfort and insulation thermal / acoustic properties recognized for cork-based floors. The invention further relates to a panel production process. 9 The expression " cork material " or simply " cork " refers to natural cork, corked natural cork, agglomerated cork, micro-agglomerated cork or the like and combinations thereof. The phrase " agglomerated cork " refers, in accordance with ISO 2190, to cork material comprising at least 51% (by weight) of cork granules with a particle size of at least 0,5 mm and a water content of not less than 8%, with the term " micro-agglomerated cork " refers to agglomerated cork, but whose cork grains have a particle size of 0.5 - 2 mm. The term " cork-based material " in the context of the present invention relates to cork material as defined above or to cork material combined with another material such as, for example, a composite material polymer and cork material. The term " polymeric material " refers to material which, according to its mechanical characteristics, can be divided into thermoplastics, thermosetting and elastomers. Thermoplastics include the known plastics, which are widely available on the market, which can be melted several times and in some cases can even dissolve in various solvents and are therefore recyclable materials. The thermosets are rigid and brittle and are very stable at temperature variations, although heating of the finished thermosetting polymer promotes the decomposition of the material prior to its melting, making its recycling complicated. As far as elastomers are concerned, these materials have a high elasticity, they are not rigid like thermosets and can not be melted, which reduces the possibility of recycling.

Note that irrespective of the explicit presentation of the quantitative expression " about X ", any X value presented in the course of the present description is to be interpreted as an approximate value of the actual X value, since such an approximation to the real value would reasonably be expected by the person skilled in the art due to experimental and / or measurement conditions which introduce deviations from the actual value. All values mentioned in the present description should be interpreted as approximate values, for example the reference to " 2.0 " means " about 2.0 ".

Unless otherwise noted, the ranges of values given in the present description are intended to provide a simplified and technically accepted way to indicate each individual value within the respective range. By way of example, the expression " 1 to 2 " or " between 1 and 2 " means any value within this range, for example 1.0; 1.1; 1,2; 1,3; 1.4; 1.5; 1.6; 1.7; 1.8; 1.9; 2.0.

In the context of the present disclosure, the term " comprising " should be understood as " including, among others ". As such, that term should not be construed as " consisting only of ".

Referring to Figs. 1 to 3, the laminated panel of the present invention comprises: a structural layer 1 of cork-based material, a base layer 2 of polymeric material disposed on a face of the layer 1 ) and a top layer (3) of polymeric material disposed on the other face of the structural layer (1), and a continuous seal layer (4) of polymeric material disposed in the transverse profile (P) defined along the entire periphery of the panel.

In one preferred embodiment, the structural layer (1) of cork-based material is a cork and polymer composite, the polymer preferably being polyvinyl chloride (also referred to as PVC).

This composite is particularly suitable since the combination of cork and PVC provides a level of additional waterproofing to the cork present in the structural layer (1) of the panel.

It will be appreciated that, depending on the combined properties required for the structural layer (1), it may combine cork material with another material selected from the group comprising polymers, natural fibers, synthetic fibers and the like and combinations thereof.

Of course, the structural layer (1) may consist only of cork material, without any combination with other materials. The base layer (2), top layer (3) and seal coating layer (4) are comprised of polymeric material selected from the group consisting of polyvinyl chloride, polyethylene, polypropylene, polystyrene, polyethylene terephthalate, ethylene vinyl acetate , polyurethane, teflon, rubber and the like and combinations thereof.

In a preferred embodiment, the base layer (2), the top layer (3) and the sealing coating layer (4) are polyvinylchloride.

Preferably, the structural layer (1) has a thickness in the range of about 1 to 5 mm, more preferably about 2 to 4 mm, even more preferably about 3 mm. The base layer (2) and the top layer (3) each preferably have a thickness in the range of about 0.4 to 2 mm, more preferably about 1 to 2 mm. Even more preferably, the base layer (2) has a thickness of about 1.2 mm and the top layer (3) has a thickness of about 1.8 mm.

As shown in Fig. 3, the laminated panel of the invention may further comprise a printed film 5 disposed on the top layer 3 and a transparent wear layer 6 disposed on the printed film 5. Alternatively, it may comprise only one of the layers (5, 6). In this way, it is possible to create patterns for the aesthetic enrichment of the floor, as well as better protect the floor from wear caused by the use. Said printed film (5) has a thickness of up to about 0.2 mm, preferably up to about 0.1 mm, and said wear layer (6) has a thickness in the range of about 0.2 to 1 mm, preferably about 0.3 to 0.8 mm, more preferably about 0.4 mm.

Referring now to Fig. 3, in a preferred embodiment, the cork impermeable panel of the invention has a structural layer (1) of a composite of polyvinyl chloride and polyvinyl chloride of 3 mm thickness, a base layer (2) of polyvinyl chloride having a thickness of 1.2 mm and a polyvinyl chloride top layer (3) having a thickness of 1,8 mm, in which a printed film (0.1 mm) is arranged, , a wear layer (6) of 0.4 mm. The joining between the different layers mentioned above can be effected by any method known in the art, wherein preferably the bonding of the layers (1, 2, 3, 5, 6) is achieved by gluing. Said bonding of the layers (1, 2, 3, 5, 6) can be effected by any other suitable method known in the art, such as, for example, heat melting. The configuration of the panel of the invention, with a structural layer (1) of cork-based material disposed between two layers (2, 3) of liquid impermeable (polymeric) material, also requires the waterproofing of its transverse profile (P) in the entire periphery of the panel (see Fig. 2), so as to ensure a reliable seal throughout the panel structure.

However, in the development of the panels of the invention, the applicant has faced two problems associated with the provision of a sealing coating layer (4) in the transverse profile (P) across the periphery of the panel. 14

On the one hand, given the nature of the cork material, it is found that the profile of a layer of, for example, cork agglomerate, has a rather rough and even discontinuous surface. This surface (which is delimited by the two polymeric layers 2,3) provides an area of poor adhesion to a seal coating layer 4, promoting the existence of adhesion discontinuity points in which the seal is locally engaged.

On the other hand, since placement of the seal coating layer (4) directly on the transverse profile (P) of the panel creates an over-thickness of coating material which materializes in joining lines between panels when assembling the floor, it is found that these lines are visible in contrast to a pattern optionally used on the visible surface of the panels or in contrast to the visible color of the panels if this is different from the color of the sealing coating layer 4 as schematically illustrated in Fig. 4. This situation is highly limiting and undesirable, especially when it is intended to provide the floor with an aesthetic standard which excludes the visibility of the joining lines of the panels constituting it. The process of producing impermeable panels of the present invention allows to overcome these problems. The production process of the impermeable laminate panels of the invention comprises combining layers of polymer materials and the cork base to provide the panel configuration previously described. Said 15 layers are arranged in a net-like structure 7 which is subsequently subjected to a cutting action in order to provide the individual impermeable panels (see Fig. 5).

With reference to Figures 5 to 8, said net 7 is made of polymeric material and comprises at least two meshes 8, wherein each mesh 8 is defined by a void space 9 delimited by (10), as shown in Figures 6 and 7.

Alternatively, the mesh 8 of the net 7 instead of being fully open may be closed at the bottom by equally polymeric material (not shown). This bottom layer integrated in the meshes (8) of the net corresponds to and performs the functions of the base layer (2). The shape and dimensions of the mesh 8 correspond to the final shape and dimensions of the panel to be obtained, whereby each mesh 8 gives rise to an individual panel 8 (see Fig. 8).

Said surrounding edges (10) establish a cutting zone in which the cutting action of the meshes (8) will be performed, thereby providing said individual laminated panels.

Thus, by taking as an example a net (7) with two square meshes (8), as shown in Fig. 7, it should be noted that it will allow to obtain two impermeable laminated panels. Each panel has the dimensions defined by the width (B) of the surrounding edges of each mesh (8) plus the width (V) of its empty space (9) (Fig. 6). The thickness (E) of the net (7) corresponds to the thickness of the structural layer (1) to the cork base 16. Naturally, structures with any number of meshes (8), as shown in Fig. 5, can be constructed depending on the available cutting capacity.

As can be seen in Fig. 7, there is a joint margin (11) common to the two meshes (8). This connecting margin 11 has at least twice the width of the remaining surrounding edge 10 of each mesh 8, whereby it defines a plurality of separating or cutting lines L of respective meshes 8, .

As will be understood, in the case of Fig. 7, after cutting and corresponding separation into two meshes (8), they give rise to an equal number of panels, in which the profile sealing coating layer (4) is provided by the edges (10). ) surrounding the meshes (8).

In this regard, a common margin (11) has an average line (M) that divides its width into two equal parts, whereby said average line (M) of the common margin (11) is preferably but not exclusive , a particular case of a line (L) for separating or cutting the meshes (8). It should be noted that any other cutting line (L) (other than the median line (M)) defined in the common edge (11) of the meshes (8) to be separated can be used to cut and separate the meshes (8 ), although it is assumed that, from the operational point of view, the average line (M) is the most important.

As will be understood, a net (7) may comprise as many meshes (8) adjacent to each other as the individual panels to be obtained. 17

Ideally, the cutting of the common edges (11) should preferably be made only by a single cutting operation, for example by slitting, so that only one cutting movement can produce as many individual panels as there are the meshes (8) of the respective net (7).

According to the foregoing and referring to Figs. 6 to 8, the method of producing waterproof laminated panels of the invention comprises the steps of: a) arranging a network (7) of polymeric material on a base layer (7) is formed by at least two adjacent meshes (8), each mesh (8) defining an empty space (9) and an edge (10) and the adjacent meshes (8) being connected by a common margin (11) defining a plurality of cut lines (L); b) integrally filling the empty space (9) defined by each of said meshes (8) with a respective structural layer (1) of cork-based material; c) disposing a top layer (3) of polymeric material on the assembly formed in step b); d) separating the meshes (8) from the net (7) by cutting into one of the cut lines (L) of the common edge (11) between adjacent meshes (8), preferably in the middle line (M), thereby forming (8) of the net (7), wherein the thickness of the structural layer (1) of cork-based material is equal to the thickness (E) of the network (7) of polymeric material and the layers 1, 2, 3) are inseparably connected to one another.

Furthermore, in a preferred embodiment, the process according to the present invention further comprises, between steps c) and d) mentioned above, an additional step of arranging a film (5) printed on the top layer (3) followed by the provision of a transparent wear layer (6) on the printed film (5). The polymeric material of said network (7) is selected from the group consisting of polyvinyl chloride, polyethylene, polypropylene, polystyrene, polyethylene terephthalate, ethylene vinyl acetate, polyurethane, teflon, rubber and the like and combinations thereof. Preferably, the polymeric material is polyvinylchloride. Said net (7) has a thickness (E) in the range of about 1 to 5 mm, more preferably about 2 to 4 mm, even more preferably about 3 mm.

In relation to the preferred material for the structural (1), top (3) and base (2) layers, the aforementioned is applied in the description of the panel. The same applies with respect to the thicknesses of the layers. 19

In order to connect the layers (1, 2, 3, 5, 6) to each other, a method of bonding using binders (or so-called binders) is preferably used. These binding agents are well known to those skilled in the art and therefore do not require further description. However, any suitable attachment means may be used to attach the layers.

Said binding agents may be selected from the group comprising polyurethane, polyester, vinylester, epoxy resins, natural resins, biomass resins and the like and combinations thereof.

With the present process, the aforementioned drawbacks are totally solved, with the additional advantage of being able to dimension without restriction the thickness of the coating layer (ie the width (B) of the surrounding edges of the meshes), once that this dimension is housed between the top (3) and base layers (2), after step c) of the present process, without any influence on the final dimensions of the panel and without being visible to the user. This gives a very significant advantage when it is desired to apply a floor of the invention in spaces subject to particularly severe humidity conditions.

The laminated panels of the present invention are particularly suitable for forming pavements. However, their applications may vary and their use, for example in walls, is also foreseeable. The disclosure herein should be understood as exemplifying and not limiting the scope of the present invention, appended hereto. of 2012 which is defined in the claims

Lisbon, July 27

Claims (18)

Laminated panel, having a periphery and a transverse profile (P) defined along the entire periphery, the panel comprising: a structural layer (1) of cork-based material, a base layer (2) of polymeric material disposed on one face of the structural layer (1) and a top layer (3) of polymeric material disposed on the other face of the structural layer (1), characterized in that it further comprises a layer (4) (P) is provided along said transverse profile (P). A panel according to claim 1, characterized in that the structural layer (1) is a composite of cork and polymer. Panel according to the preceding claim, characterized in that said polymer is polyvinyl chloride. Panel according to claim 1, characterized in that the base layer (2) is polyvinyl chloride. Panel according to claim 1, characterized in that the top layer (3) is polyvinyl chloride. 1 Panel according to claim 1, characterized in that the structural layer (1) has a thickness in the range of 1 to 5 mm. Panel according to claim 1, characterized in that the base layer (2) and the top layer (3) each have a thickness in the range of 0.4 to 2 mm. A panel according to claim 1, characterized in that it comprises a structural layer (1) of a composite of polyvinyl chloride and polyvinyl chloride having a thickness of 3 mm, a layer (2) of polyvinyl chloride base of 1,2 mm of thickness and a polyvinyl chloride top layer (3) of 1.8 mm thickness. A panel according to any one of the preceding claims, further comprising a printed film (5) disposed on the top layer (3) and a transparent wear layer (6) disposed on the printed film (5). Panel according to the preceding claim, characterized in that the printed film (5) has a thickness of up to 0.1 mm and the wear layer (6) has a thickness in the range of 0.2 to 1 mm. Panel according to any one of the preceding claims, characterized in that said layers (1, 2, 3, 5, 6) are glued together. 2 A panel according to claim 1, characterized in that it is used in a modular way to form a floor. Process for producing laminated panels as claimed in any one of the preceding claims, characterized in that it comprises the steps of: a) arranging a web (7) of polymeric material on a base layer (2) of polymeric material, the network (7) a certain thickness (E) and the net (7) being formed by at least two adjacent meshes (8), each net (8) defining an empty space (9) and a surrounding edge (10) and being the adjacent meshes (8) connected by a common margin (11) defining a plurality of cut lines (L); b) integrally filling the empty space (9) defined by each of said meshes (8) with a respective structural layer (1) of cork-based material; c) disposing a top layer (3) of polymeric material on the assembly formed in step b); d) separating the meshes 8 from the net 7 by cutting into one of the cut lines L of the common margin 11 between adjacent meshes 8, forming as many panels as the meshes 8 of the net 7, , wherein the thickness of the structural layer (1) of cork-based material is equal to the thickness (E) of the network (7) of polymeric material and the layers (1, 2, 3) are inseparably joined together . A process according to claim 13, characterized in that the polymeric material of said network (7) is polyvinyl chloride. A method according to claim 13, characterized in that the web (7) of polymeric material has a thickness (E) in the range of 1 to 5 mm. A method according to claim 13, characterized in that the structural layer (1) is a composite of cork and polymer. A process according to claim 16, characterized in that said polymer is polyvinyl chloride. A process according to claim 13, characterized in that the base layer (2) and the top layer (3) are polyvinylchloride. Method according to claim 13, characterized in that the base layer (2) and the top layer (3) each have a thickness in the range of 0.4 to 2 mm. 4 19.