RU2792793C2 - Substrate based on plastic composition and solid composition on mineral base for decorated wall or floor panels - Google Patents

Abstract

FIELD: floor panels.

SUBSTANCE: present invention relates to a base material for production of a decorated wall or floor panel. The base material may contain a matrix material and a solid material, and the matrix material is present in an amount of from≥ 25% to < 55% by weight of the base material, the solid material is present in an amount of from≥ 45% to≤ 75% by weight of the base material. The matrix material and the solid material together may be present in an amount≥ of 95% by weight of the base material. The base material is different in that the solid material is formed by at least 50% by weight of the solid material from a solid composition consisting of at least the first layered silicate powder and the second layered silicate powder, and the matrix material is formed by at least 50% by weight of the matrix material of the plastic composition, consisting of a homopolymer and at least the first copolymer and the second copolymer. In this case, additional substances are additionally present in the base material in an amount of up to <5% by weight of the base material.

EFFECT: invention makes it possible to manufacture load-bearing boards for wall or floor panels based on the claimed material, which have good mechanical properties and good manufacturability, and also have improved elastic properties compared to known mineral-polymer composites.

16 cl, 2 dwg

Description

The present invention relates to a base material for the production of a decorated wall or floor panel, as well as to a wall or floor panel containing such a base material.

Decorated panels are known, and the term wall panel also means panels that are suitable for door or ceiling cladding. They usually consist of a backing or core of a hard material, such as wood material, which is provided on at least one side with a decorative layer and a protective layer, and optionally additional layers, such as a wear layer, located between the decorative and protective layer. The decorative layer is usually printed paper impregnated with resin. The top layer and other layers are usually also made of resin.

From EP 2829415 A1 there is further known a method for the production of a decorated wall or floor panel, in which a base is formed from a granular base material and then a panel. In such a method, for example, WPC (Wood Plastic Composite) can be used as a base material.

From EP 3147135 A1 a base material is known in which talc is used as a mineral filler in a polymer matrix and is suitable for the production of decorated wall and floor panels.

Under certain circumstances, panel production may still offer potential for improvement. Potential for improvement may arise, in particular, in terms of the elastic properties of the wall or floor panels.

Therefore, it is an object of the present invention to provide an improved base material for the production of decorative wall or floor panel backing boards, which would allow the production of decorated wall or floor board backing boards with improved elastic properties.

This task is solved by the base material according to claim 1 and additionally by the panel according to claim 15. Preferred embodiments of the present invention are defined in the dependent claims, in the description or in the drawings, with additional features described or shown in the dependent claims , in the description or in the drawings, may individually or in any combination represent the subject of the present invention, unless otherwise apparent from the context.

The present invention provides a base material for producing a base for a decorated wall or floor panel.

The base material contains a matrix material and a solid material, the matrix material being present in an amount of ≥ 25 wt.% to ≤ 55 wt.%, in particular from ≥ 35 wt.% to ≤ 45 wt.%, by weight of the base material, and wherein the solid material is present in an amount of ≥ 45 wt.% to ≤ 75 wt. ≥ 95 wt.% by weight of the base material, in particular ≥ 99 wt.%, and the solid material is formed by at least 50 wt.%, in particular at least 80 wt.%, in particular at least 95 wt.% from a solid composition consisting of at least a first layered silicate powder and a second layered silicate powder, and the matrix material is formed by at least 50 wt.%, in particular at least 80 wt.%, in particular at least at least 95 wt.% from a plastic composition consisting of a homopolymer and at least the first copo polymer and the second copolymer.

Surprisingly, it has been found that, on the basis of such a base material, carrier boards for wall or floor panels can be produced which, while having good mechanical properties such as dimensional stability, in particular with respect to humidity and temperature, and good workability, have improved elastic properties. properties compared to known mineral-polymer composites. Elastic properties can be described, for example, by flexural modulus, flexural strength, or flexural strain. The good workability of the base plate may be due, in particular, to the preferred mass flow rate of the base material. In addition, the base formed on the basis of such a base material may have a preferred toughness. A panel made from this base material can have good bond strength.

In the sense of the present invention, the term "decorated wall or floor panel" or "decorative panel" is to be understood in particular as a wall, ceiling, door or floor panel containing a decorative finish that replicates the finish pattern and is applied to the base board. Decorative panels are used in a variety of ways, both in the design of interiors of rooms, and for decorative cladding of buildings, for example, in the construction of exhibition stands. One of the most common applications for decorative panels is their use as flooring. In this document, decorative panels often contain finishes that replicate natural material.

Examples of such replicated natural materials or finishes are woods such as maple, oak, birch, cherry, ash, walnut, chestnut, wenge, or even exotic woods such as panga panga, mahogany, bamboo and bubinga. In addition, natural materials such as stone surfaces or ceramic surfaces are often copied.

Accordingly, a "finish pattern" in the sense of the present invention can be understood in particular as such a natural raw material, or at least its surface, which is to be imitated or reproduced by the finish.

A "fluid" material can in particular be understood as a material that can be applied to a surface by a casting or surface spreading process. In this case, the material may be present as a fluid or, in particular, as a free-flowing solid.

In addition, "granulate" or "granular material" can be understood as a solid body or heap of solid matter, which contains or consists of many solid particles, such as grains or spheres. As a non-exhaustive example, granular or powdery materials may be mentioned here.

A "substrate" may in particular be understood as a layer which serves as a core or base layer in a finished panel and may in particular comprise a natural material such as a wood based material, a fibrous material or a plastic containing material. For example, the base material may already impart suitable stability to the base or may contribute to it.

Accordingly, the base material can be understood as the material that forms the base, at least in a predominant part. In particular, the base may consist of a base material.

A "web-shaped backing" can be understood as a backing which, for example, during its production is in the form of a web, and therefore considerably longer than its thickness or width, and whose length can be, for example, more than 15 m.

In the sense of the present invention, a "board-shaped substrate" can be understood as a substrate that is formed by dividing a web-shaped substrate and has the shape of a board. In addition, the slab-shaped substrate may already determine the shape and/or size of the panel to be produced. However, a slab-shaped base may also be provided as a large slab. A large slab in the sense of the present invention is in particular a base whose dimensions are several times larger than the final decorative panels and which is divided during the manufacturing process into a corresponding plurality of decorative panels, for example by sawing, laser or water jet cutting. For example, a large slab may correspond to a web-shaped base.

The previously described base material thus serves, in particular, for the production of a base for a decorated wall or floor panel. The base material contains essentially two materials, and the material in the sense of the present invention can be understood both as a homogeneous material, that is, a material formed from only one substance, and as a heterogeneous material, that is, a material consisting of at least two substances, and the latter material can thus also be understood as a mixture of substances.

In more detail, the base material comprises a solid material and a matrix material. In this case, the matrix material is present in an amount of from ≥ 25 wt.% to ≤ 55 wt.%, in particular from ≥ 35 wt.% to ≤ 45 wt.% by weight of the base material. While the solid material is present in an amount of from ≥ 45 wt.% to ≤ 75 wt.%, in particular from ≥ 55 wt.% to ≤ 65 wt.% by weight of the base material.

Depending on the required application and the desired properties of the panel, the proportions of matrix material or solid material may vary. As a result, good adaptability to the required application becomes possible. In principle, however, it may be preferable that the proportion of solid material be greater than or equal to the proportion of matrix material.

Additionally, it is ensured that the matrix material and the solid material together are present in an amount of ≥ 95% by weight, in particular ≥ 99% by weight, based on the weight of the base material.

In other words, in addition to the solid material and the matrix material, additional substances may only be present in the base material in an amount of <5 wt.%, preferably <1 wt.%, by weight of the base material. Thus, it may be preferable that the base material consists to a large extent of a solid material and a matrix material. It is particularly preferred that the matrix material and the solid material are present together in an amount of 100% by weight of the base material, ie that the base material consists of the matrix material and the hard material.

By limiting the number of materials of the base material, the production of the base can be made particularly cost-effective. In addition, the process control of the base or panel production can be very simple, so that easy and cost-effective production can be ensured.

In more detail, it is additionally provided that the solid material is formed by at least 50 wt.%, in particular at least 80 wt.%, in particular at least 95 wt.% by weight of the solid material from a solid composition consisting of at least one of the first layered silicate powder and the second layered silicate powder.

Layered silicate powder should be understood in the usual way as layered silicate powder. Layered silicate is known and refers to minerals from the group of silicates, the silicate anions of which are usually arranged in layers. For example, layered silicates are understood to be minerals from the mica group, the chlorite group, the kaolinite group, and the serpentine group.

Thus, the solid material is preferably formed by at least a significant portion of the layered silicate mineral substance, which substance may be used, for example, in the form of a powder or may be present in the base material in the form of particles. In principle, the solid material may consist of a powdered solid.

The advantage of layered silicates is that they allow the production of a base with good mechanical properties, and at the same time can be suitably processed into suitable powders due to their layered structure.

In one embodiment of the present invention, the first layered silicate powder or the second layered silicate powder may contain talc. Talc is known to be magnesium silicate hydrate, which may have, for example, the chemical formula Mg ₃ [Si ₄ O ₁₀ (OH) ₂ ]. In one additional embodiment of the present invention, the first layered silicate powder and the second layered silicate powder may contain talc. In one preferred embodiment, the first layered silicate powder and the second layered silicate powder consist of at least 80% by weight of talc, and particularly preferably at least 95% by weight of talc.

In particular, the advantage of talc is that it makes it possible to manufacture the base in a particularly gentle manner, since it can be embedded in the matrix material without problems and thus does not have an abrasive effect on the pressing devices used.

In one embodiment of the present invention, the solid composition may contain a first layered silicate powder in an amount from ≥ 35 to ≤ 85 wt.%, preferably ≥ 50 to ≤ 70 wt.%, for example, 60 wt.% by weight of the solid composition, and the second layered silicate powder in an amount from ≥ 15 to ≤ 65 wt.%, preferably ≥ 30 to ≤ 50 wt.%, for example, 40 wt.% by weight of the solid composition.

The first layered silicate powder may preferably be present in the solid composition in the form of particles having a particle size D ₅₀ in the range of ≥ 3 μm to ≤ 6 μm, preferably in the range of ≥ 4 μm to ≤ 5 μm, for example 4.5 μm, and /or having a particle size D ₉₈ in the range from ≥ 10 μm to ≤ 30 μm, preferably in the range from ≥ 15 μm to ≤ 20 μm, for example, 17 μm. The first layered silicate powder may preferably be present in the solid composition in the form of particles having a particle size D ₅₀ in the range of ≥ 6 μm to ≤ 10 μm, preferably in the range of ≥ 7 μm to ≤ 9 μm, for example 8 μm, and/or having a particle size D ₉₈ in the range from ≥ 20 μm to ≤ 40 μm, preferably in the range from ≥ 25 μm to ≤ 35 μm, for example, 28 μm.

In particular, by using a layered silicate powder with particles of a predetermined size distribution, it is possible to produce substrates or panels with preferred mechanical properties.

By providing the first and second layered silicate powders in the form of different particles for the solid composition, depending on the desired application and the desired properties of the panel, the proportions of the first and second layered silicate powders can be selected. As a result, good adaptability to the required application becomes possible. In principle, however, it may be preferable that the proportion of the first layered silicate powder in the mass of the solid composition is greater than or equal to that of the second layered silicate powder. Furthermore, it may be preferred in principle that the first layered silicate powder is present in the form of particles having a particle size D ₅₀ smaller than the particle size D ₅₀ of the second layered silicate powder.

To determine the particle size distribution, one can rely on well-known methods, such as, for example, laser diffractometry, by which particle sizes in the range from a few nm to a few mm can be determined. This method can also be used to determine D ₅₀ or D ₉₈ values, which respectively indicate that 50% (D ₅₀ ) or 98% (D ₉₈ ) of the measured particles are finer than the specified value. The same applies to determining grain size or average grain size. These values can also be preferably determined by laser diffractometry. In the event of a deviation in the measured values obtained by means of different measurement methods, the value determined by means of laser diffractometry is considered by the Applicant to be decisive.

It may be preferable that the specific surface density according to ISO 4352 (BET) of the particles of the first and/or second layered silicate powder is in the range from ≥ 4 m ² /g to ≤ 8 m ² /g, approximately in the range from ≥ 5 m ² /g to ≤ 7 m ² /g.

In addition, it may be preferable that the first layered silicate powder has a bulk density according to DIN 53468 in the range from ≥ 2.4 g/cm ³ to ≤ 3.6 g/cm ³ , for example, in the range from ≥ 2, 9 g/cm ³ to ≤ 3.1 g/cm ³ . In addition, it may be preferable that the second layered silicate powder has a bulk density according to DIN 53468 in the range from ≥ 3.4 g/cm ³ to ≤ 4.6 g/cm ³ , for example, in the range from ≥ 3, 9 g/cm ³ to ≤ 4.1 g/cm ³ . In particular, the first layered silicate powder may have a bulk density according to DIN 53468 less than or equal to the bulk density of the second layered silicate powder.

The matrix material serves in particular to accommodate or pour solid material into the final substrate. The matrix material in this case contains a plastic composition. In particular, with regard to the production method detailed below, it may be preferable that the matrix material contains a thermoplastic. This allows the base material or base material component to have a melting point or softening point such that the base material can be further formed by heating, as detailed below with reference to the method. The matrix material may in particular consist of a plastic composition and optionally a binder.

In more detail, it is envisaged that the matrix material is formed by at least 50 wt.%, in particular at least 80 wt.%, in particular at least 95 wt.% by weight of the matrix material from a plastic composition consisting of a homopolymer and at least a first copolymer and a second copolymer.

The previously described base material offers in particular the advantage of obtaining a panel with good moisture resistance. In particular, by using the base material described above, swelling of a panel made from this base material due to moisture can be significantly reduced or even completely prevented. In addition, heat-related expansion can be prevented or at least greatly reduced. This makes it possible to significantly simplify the process of laying or attaching panels produced with this base material and/or significantly reduce problems after laying or attaching panels.

At the same time, the base material has the advantage that panels made from it have very good stability, so that the risk of damage to the panel during transport and during use is extremely low. This can be achieved in particular by the hard material, that is to say in particular by the first and second layered silicate powders contained. As a result, in particular, it can be achieved that the panels made from them have an advantageous impact strength. For example, based on this base material, a panel with an impact strength of ≥ 11 kJ/m ² to ≤ 13 kJ/m ² , preferably ≥ 11.5 kJ/m ² to ≤ 12.0 kJ/m ² , can be provided.

In accordance with one embodiment of the present invention, it can in particular be provided that the homopolymer, the first copolymer and/or the second copolymer consist at least in part of recycled material. In accordance with one additional embodiment of the present invention, the proportion of recycled material in each type of polymer or copolymer can be from ≥ 2 wt.% to ≤ 100 wt.%, preferably from ≥ 5 wt.% to ≤ 90 wt.%, in particular from ≥10 wt.% to ≤ 80 wt.%, for example, from ≥ 15 wt.% to ≤ 70 wt.%. It can also be provided that the proportion of recycled material is different for each type of polymer or copolymer. In particular, it can be provided that at least one type of polymer or copolymer contains ≤ 90 wt.% recycled material, while other types of polymer or copolymer independently of each other contain ≥ 50 wt.%, in particular ≥ 10 wt. .% recycled.

Due to the fact that the matrix material in particular contains a plastic such as a thermoplastic, despite a large margin of stability, it can be ensured that the panels produced from this base material are very resilient or resilient and/or bendable, which ensures a comfortable impression and further reduces noises when walking on them compared to conventional materials, and thus an improved sound of footsteps can be realized.

In particular, thermoplastics also have the advantage that products made from them can be recycled very easily. This leads to an additional opportunity to reduce production costs.

In addition, a base made from this base material can be provided with a decorative finish without any problem. For example, such a substrate is very suitable for printing, in particular with a digital printing process such as an inkjet printing process. As a result, such substrates can be easily provided with a high quality decorative finish, allowing the production of a high quality panel.

In particular, a mixture of homopolymer, first copolymer and second copolymer for the matrix material can provide particularly advantageous properties. Such materials also have the advantage that they can be converted to the base even at low temperatures, for example in the range of ≥ 180°C to ≤ 200°C, in the process described above, so that particularly effective process control can be achieved, for example , with approximate linear speeds in the range of 6 m/min. Efficient process control can be achieved in particular due to the fact that the base material has a preferred mass flow rate. By means of a mixture of homopolymer, first copolymer and second copolymer, it can be achieved, for example, that the base material has a mass flow rate of ≥ 20 g/10 min to ≤ 30 g/10 min, preferably ≥ 24 g/10 min to ≤ 26 g /10 min. In particular, the use of at least two copolymers may be preferred, since this makes it possible to achieve improved elastic properties of the base obtained. In particular, panels produced using this base material can be achieved to have a preferred flexural modulus. Based on this base material, for example, a panel having a flexural modulus of ≥ 3000 MPa to ≤ 4000 MPa, preferably ≥ 3400 MPa to ≤ 3600 MPa can be provided. In addition, panels produced using this base material can be achieved to have an advantageous bending strength. Based on this base material, for example, a panel having a bending strength of ≥ 30 MPa to ≤ 34 MPa, preferably ≥ 31 MPa to ≤ 33 MPa, can be provided. In addition, it is possible to achieve that panels produced using this base material have a preferable flexural deformation. Based on this base material, for example, a panel having a bending strain of ≥ 2.0% to ≤ 2.8%, preferably ≥ 2.3% to ≤ 2.5% can be provided.

It may be preferred that the homopolymer, the first copolymer and the second copolymer include polypropylene. Polypropylene is particularly suitable as a matrix material because on the one hand it is available at low cost and on the other hand it has good properties as a thermoplastic matrix material for pouring solid material.

In particular, by using a homopolymer, a high melt flow rate can be achieved, whereby the melt flow rate of the homopolymer can in particular be higher than that of the first copolymer and the second copolymer. This can provide particularly good formability of the substrate during the manufacturing process. In addition, the homopolymer can thus provide a particularly good casting of the solid material. It may therefore be particularly preferred that the homopolymer has a melt mass flow rate of ≥ 20 g/10 min, particularly preferably ≥ 50 g/10 min, for example 52 g/10 min. The mass flow rate of the melt can be determined in accordance with ISO 1133.

In addition, it may be preferable that the homopolymer has a tensile strength according to ISO 527-2 in the range of ≥ 30 MPa to ≤ 45 MPa, for example in the range of ≥ 35 MPa to ≤ 40 MPa, in order to achieve good stability.

In addition, in particular in terms of good stability, it may be preferable that the homopolymer has a flexural modulus according to ISO 178 in the range of ≥ 1200 MPa to ≤ 2200 MPa, for example ≥ 1400 MPa to ≤ 2000 MPa, in in particular from ≥ 1600 MPa to ≤ 1800 MPa.

With regard to the tensile strain of the homopolymer according to ISO 527-2, it may also be preferred that it be in the range of ≥ 5% to ≤ 13%, for example, in the range of ≥ 8% to ≤ 10%.

For particularly advantageous processability, it is desirable that the Vicat heat resistance of the homopolymer according to ISO 306/A for the injection molded component is in the range ≥ 130°C to ≤ 170°C, for example ≥ 145°C to ≤ 158 °C.

In contrast, the first copolymer may in particular provide mechanical strength to the base material or to the base itself. In particular, the melt flow rate of the first copolymer may be less than that of the second copolymer and homopolymer. This can ensure that a particularly good mechanical strength of the base material or base material is achieved.

In addition, it may be particularly preferred that the first copolymer has a melt mass flow rate from ≥ 4 g/10 min to ≤ 12 g/10 min, for example, from ≥ 6 g/10 min to ≤ 9 g/10 min, for example, 7.5 g/10 min. The mass flow rate of the melt can be determined in accordance with ISO 1133.

In addition, in particular for good stability, it may be preferable that the first copolymer has a tensile modulus according to ISO 527-1, -2 in the range of ≥ 900 MPa to ≤ 1400 MPa, for example ≥ 1100 MPa to ≤ 1250 MPa.

With regard to the tensile strength according to ISO 527-2 of the first copolymer, it may also be preferred that it be in the range of ≥ 15 MPa to ≤ 27 MPa, for example ≥ 18 MPa to ≤ 24 MPa. In particular, the tensile strength of the second copolymer may be less than that of the homopolymer.

For the preferred processability, it may also be preferable that the heat resistance of the first copolymer, in particular the heat deformation temperature B (0.45 MPa) without tempering in accordance with ISO 75B-1, -2, is in the range from ≥ 50°C to ≤ 110°C, e.g. ≥ 70°C to ≤ 90°C.

It may be particularly preferred that the first copolymer has a Rockwell ball indentation hardness according to ISO 2039-1 ≥ 15 MPa, eg ≥ 30 MPa, and more preferably ≥ 40 MPa. In particular, the Rockwell hardness of the first copolymer may be greater than that of the homopolymer.

For particularly advantageous processability, it is desirable that the heat resistance of the first Vicat copolymer according to ISO 306/A for the injection molded component is in the range ≥ 125°C to ≤ 165°C, for example ≥ 140°C to ≤ 150°C.

Therefore, it may be particularly preferred that the first copolymer contains a heterophasic polypropylene. In addition, it may be preferred that the first copolymer contains at least 95 wt.%, and preferably at least 99 wt.% heterophasic polypropylene.

In contrast, the second copolymer may in particular provide the elastic properties of the base material or base. In particular, the melt flow rate of the second copolymer may be less than that of the homopolymer and greater than that of the first copolymer. This can provide particularly good elastic properties of the base material or base.

In addition, it may be particularly preferred that the second copolymer has a melt mass flow rate of ≥ 7 g/10 min, particularly preferably ≥ 19 g/10 min, for example 20 g/10 min. The mass flow rate of the melt can be determined in accordance with ISO 1133.

In addition, it may be particularly preferred that the second copolymer has a Shore A hardness according to ASTM D2240 of ≥ 55 to ≤ 75, more preferably ≥ 60 to ≤ 70, such as 66.

As for the tensile strength of the second copolymer according to ASTM D638, it may also be preferable that it be in the range of ≥ 4 MPa to ≤ 7 MPa, and more preferably ≥ 5 MPa to ≤ 6 MPa, for example, 5, 5 MPa.

For particularly advantageous processability, it is desirable that the heat resistance of the second Vicat copolymer according to ISO 306/A or ASTM D1525 for the injection molded component is in the range ≥ 40°C to ≤ 54°C, for example ≥ 45° C to ≤ 49°C.

Therefore, it may be particularly preferred that the second copolymer comprises an ethylene-propylene copolymer and an isotactic polypropylene. In addition, it may be preferred that the second copolymer contains at least 95 wt.%, preferably at least 99 wt.% of a mixture consisting of a copolymer of ethylene and propylene and isotactic polypropylene. It is particularly preferred that the second copolymer has an ethylene content of from ≥ 8 wt.% to ≤ 22 wt.%, preferably from ≥ 13 wt.% to ≤ 17 wt.%, for example, 15 wt.%.

In this way, even within the matrix material, a particularly simple and good control of the properties of the matrix material and thus of the base material can be possible. Such control can thus be achieved by simply selecting the appropriate homopolymer, or the first copolymer and the second copolymer, as well as selecting their respective weight fractions.

With regard to the distribution of the homopolymer, the first copolymer and the second copolymer, it may be preferable that the homopolymer is present in an amount of ≥ 10 wt.% to ≤ 40 wt.% by weight of the plastic composition, for example, from ≥ 20 wt.% to ≤ 25 wt. %, and/or that the first copolymer is present in an amount of from ≥ 40 wt.% to ≤ 70 wt.% by weight of the plastic composition, for example, from ≥ 50 wt.% to ≤ 60 wt.%, and/or that the second copolymer is present in an amount from ≥ 10 wt.% to ≤ 40 wt.% by weight of the plastic composition, for example, from ≥ 20 wt.% to ≤ 25 wt.%.

For example, the proportion of homopolymer may be 22 wt.%, the proportion of the first copolymer may be 55 wt.%, and the proportion of the second copolymer may be 23 wt.%.

In particular, with such a configuration of the plastic composition, particularly advantageous properties of the matrix material can be achieved. In more detail, it has surprisingly been found that in particular the proportions of homopolymer or first copolymer and second copolymer described above combine good processability with good stability and resilience.

In addition, it may be preferred that the density of the first copolymer is greater than or equal to the density of the homopolymer and/or the density of the second copolymer is less than or equal to the density of the homopolymer. This feature can also lead to a particularly advantageous processability in combination with particularly advantageous mechanical properties, in particular a particularly good stability of the panel produced using the base material described above. For example, the homopolymer density according to ISO 1183 can range from ≥ 0.85 g/cm ³ to ≤ 0.95 g/cm ³ , for example ≥ 0.89 g/cm ³ to ≤ 0.91 g /cm ³ , for example, 0.900 g/cm ³ . In addition, for example, the density of the first copolymer according to ISO 1183 can be in the range from ≥ 0.86 g/cm ³ to ≤ 0.96 g/cm ³ , for example, from ≥ 0.895 g/cm ³ to ≤ 0.915 g/cm ³ , for example 0.905 g/cm ³ . In addition, for example, the density of the second copolymer according to ISO 1183 may be in the range from ≥ 0.82 g/cm ³ to ≤ 0.90 g/cm ³ , for example, from ≥ 0.85 g/cm ³ to ≤ 0.87 g/cm ³ eg 0.863 g/cm ³ .

In addition, it may be preferred that the matrix material has at least one color additive in addition to the plastic composition. The color additive may preferably be a pigment formulation based on thermoplastic base materials. A pigment composition based on thermoplastic base materials is to be understood in a known manner as a colored granulate or so-called concentrate, which contains a plastic granulate as a base material, which contains, in particular, colored pigments in the highest possible concentration.

In this way, it can be achieved that the base material is colored and can be used to produce a colored base in a process for producing a decorated wall or floor panel. By means of a preferred coloring additive, in particular in the form of a pigment composition based on thermoplastic base materials, it is possible to achieve that the colored base has a particularly uniform color.

The plastic granules of the color additive may preferably contain polypropylene or polyethylene. Preferably the color pigments are lead and/or cadmium free. The color pigments used may contain, for example, copper phthalocyanine, quinacridone and/or diketopyrrolopyrrole. As a result, it can be achieved that the base material can be recycled in an environmentally friendly manner.

The coloring additive may preferably have a heat resistance up to at least 230°C, preferably at least 280°C, and a melting point range of ≥ 95°C to ≤ 125°C, preferably ≥ 105°C to ≤ 115°C. By means of such a coloring additive, it can be achieved that the method for producing a decorated wall or floor panel only slightly changes the color, so that the color of the base material matches the color of the base made from it.

It is particularly preferred that the coloring additive is present in the matrix material in an amount of <50 wt.%, in particular <20 wt.%, for example <10 wt.%, for example <5 wt.%. In this way, it can be achieved that the mechanical properties of the colored base material remain virtually unchanged compared to the uncolored base material.

In addition, it may be preferred that the matrix material contains polyethylene in the form of LDPE. Such materials have the advantage that they can already be converted to the base at low temperatures, for example in the range from ≥ 180°C to ≤ 200°C, in the process described above, so that particularly effective process control can be achieved, for example, with approximate linear speeds in the range of 6 m/min. In addition to this, LDPE is available at a low cost.

In particular, when the matrix material contains LDPE, the matrix material may not contain a binder. This embodiment can make the base material particularly cost-effective since it is possible to dispense with a component that must be added to the matrix material depending on the polymer of the matrix material used. In addition to this, the provision of the base material can be further simplified.

In addition, the base material may consist of at least a matrix material, a solid material, and optionally a binder. In particular, in this embodiment, the production can be particularly cost-effective and the process control can be particularly simple, because the base material only consists of a solid composition, a plastic composition and, in particular depending on the plastic used, a binder which can be chosen for a given plastic in a known manner.

It may also be preferred that the solid material contains an additional solid in addition to the first layered silicate powder and the second layered silicate powder. For example, the additional solid may be selected from the group consisting of wood, for example in the form of wood flour, tuff, pumice, cellular concrete, in particular inorganic foam, and cellulose. With regard to cellular concrete, it may be, for example, a solid substance used by Xella under the brand name Ytong, which consists essentially of quartz sand, lime and cement. With regard to the added solid, it may, for example, consist of particles having the same particle size or particle size distribution as described above for layered silicate powders. Additional solids may be present in the solid material in particular in an amount of <50 wt.%, in particular <20 wt.%, for example, <10 wt.% or <5 wt.%.

Alternatively, it can be provided, for example, for wood, in particular for wood flour, that its particle size ranges from > 0 µm to ≤ 600 µm, with a preferred particle size distribution D ₅₀ ≥ 400 µm.

In addition, the base material may contain from ≥ 0 wt.% to ≤ 10 wt.% additional additives, such as flow agents, heat stabilizers or UV stabilizers.

For example, the base material may be present in the form of a granulate, in which case it may be cylindrical. In addition, regardless of the shape, but for example in a cylindrical shape, the granular particles may have a diameter in the range of ≥ 2 mm to ≤ 3 mm, such as 2 mm or 3 mm, and a length of ≥ 2 mm to ≤ 9 mm, for example , ≥ 2 mm to ≤ 7 mm or ≥ 5 mm to ≤ 9 mm.

Thus, the base material described above offers the advantage of good processability in combination with high dimensional stability, in particular with regard to the influence of moisture and temperature, as well as good mechanical and elastic properties.

With regard to additional technical characteristics and advantages of the above-described base material, reference is expressly made here to the panel description, method and drawings.

The present invention further relates to a decorated panel, in particular a decorated wall or floor panel, comprising a base and a decorative finish applied to the base, in which in particular a protective layer provided with a structure is applied to the decorative finish. Such a panel is characterized in that the base comprises a base material as described in detail above. Thus, with reference to specific features, reference is made to the above description.

In addition, the edge regions of the panel can be structured or profiled in order to provide in particular detachable connecting elements. In this regard, when profiling in the sense of the present invention, it can be provided that, at least in part of the edges of the decorative panel, a decorative and/or functional profile is formed with suitable tools for removing material. In the present document, a functional profile means, for example, the formation of a groove and/or a protrusion on the edge in order to make the decorative panels connected to each other by means of the formed profiles. Here, in particular with groove and/or protrusion profiles, elastic materials have an advantage, since only with them can profiles be produced that are particularly easy to handle and are stable. Thus, no additional materials are required for the manufacture of the connecting elements. The base material can thus provide panels that have a joint strength according to ISO 24334 for a joint gap of 0.2 mm ≥ 2.0 kN/m, preferably ≥ 4.0 kN/m in the longitudinal direction and ≥ 2, 5 kN/m, preferably ≥ 4.5 kN/m in transverse direction.

Thus, the above-described panel can provide the advantage of high dimensional stability in terms of heat and moisture influence, and at the same time good mechanical properties. In addition, such a panel can be very stable and at the same time have high tensile, compressive and flexural strength and/or notched impact strength. At the same time, this panel can have a high degree of resilience and/or softness in bending, which can be advantageous, in particular, for an efficient and cost-effective design of the connecting elements in the edge region of the base, as well as for soundproofing steps.

With regard to additional technical characteristics and advantages of the panel, reference is made explicitly here to the description of the base material, the method and the drawings.

The present invention further provides a method for producing a decorated wall or floor panel, comprising the steps of:

a) providing a flowable base material, in particular a granulate, the base material being configured as detailed above,

b) positioning the base material between two conveyor belts,

c) forming the base material under the action of temperature in the base in the form of a web,

d) warp compression,

e) pressurizing the warp using a double belt press,

f) optional base cooling,

g) optionally applying a decorative finish to at least a portion of the base;

h) optionally applying a decorative pattern reproducing a decorative pattern to at least a portion of the base, and

i) optionally applying a protective layer to at least a portion of the decorative trim.

In addition, the following steps may take place:

j) structuring the protective layer, and

k) treating the substrate against electrostatic discharge and, optionally, against electrostatic charge before at least one of the above steps, in particular before one of steps d) to i), for example, before step h).

Surprisingly, it has been shown that the method described above provides a particularly advantageous production, in particular of the base for a wall or floor panel. In this case, this method may be particularly advantageous when using the base material detailed above.

In particular, it has been found that the method described herein makes it possible to obtain a particularly smooth and defined customizable substrate surface, which, for example, can be particularly advantageous for further processing into a panel, especially when decorating, for example, by direct printing.

In accordance with the present method, the base or core is first produced. To this end, the method described above comprises, according to step a), first providing a flowable base material. The base material serves as the basis for the production, in particular, of bases for panels in the form of slabs. In this regard, reference is made entirely to the above formulations.

In one particularly preferred embodiment, the base material can be provided as a flowable solid or as granules, the granules depending on the material used having, for example, a particle size in the range of ≥ 100 µm to ≤ 10 mm. The preferred filling or distribution of the base material may have a bulk density deviation of ≤ 5%, in particular ≤ 3%.

According to step b) of the process, a fluid, in particular granular, base material is placed between two conveyor belt means. In more detail, the lower conveyor belt moves in an annular manner, and at a certain distance from it, the upper conveyor belt moves in an annular manner. The base material may be applied to the lower conveyor means and then limited to the lower and upper conveyor means. Due to the precise dispersion, side limiters can be dispensed with. Thus, by means of these two conveying means, the base material can be transported to or through the individual processing stations and processed into the base. In addition, the base material may already be preformed at this stage of the process. Thus, belt conveyor means can perform two functions - transport and molding.

In this case, the belt conveyor means, at least in the area of the double belt press, as will be described below, may be at least partially made of Teflon or polytetrafluoroethylene (PTFE). For example, belts may be formed entirely from PTFE, or belts provided with a PTFE outer cover may be used. In the latter case, glass fiber reinforced plastic belts or PTFE coated steel belts can be used. By means of such conveying means, a particularly defined, for example smooth, surface of the produced substrate can be obtained due to the anti-adhesion properties of this material. In this way, it is possible to prevent the carrier material being transported from sticking to the conveyor means, and thus adversely affecting the surface structure directly or by sticking the material in the next cycle. In addition, PTFE is resistant to chemicals as well as to decomposition even at high temperatures, so that, on the one hand, heat treatment of the base material can be carried out without any problems, and on the other hand, the conveying means remain stable in over a long period of time. In addition to this, you can freely choose the base material.

The pipeline means may pass through the entire device, or may be interrupted and configured as a plurality of pipeline means.

the arrangement of the base material in accordance with step b) can be implemented, in particular, by means of one or a plurality of dispersing heads, which can release the base material in a certain way, for example, from storage containers. In this case, a doctor blade can be additionally provided, which cleans the material in the recesses of the roller. The material can then be discharged by means of a rotating brush roller from the spreading roller, whereby it hits a baffle and slides from there onto the conveyor means. In addition, for adjusting the width, an adjustment of the dispersion width can be provided. In this embodiment, a particularly uniform discharge of the base material can take place, which can also result in a uniform base of a certain quality.

For example, one diffusing head may be provided, or two, three or more diffusing heads may be provided. As a result, the base can be adapted particularly easily to specific needs, for example by providing the required mixture of materials. In this embodiment, the mixture can be adapted without any problems during the production process or between two batches, so that particularly great flexibility can be achieved. In addition, by varying the equipment of the individual diffuser heads, the base material mixture can only be obtained immediately before processing, so that the mutual negative influence of the various components and the reduction in the quality of the produced base material can be prevented.

For example, a sensor for checking the location of the base material may be provided between two conveyor belt means, such as a sensor for the bulk of the applied material or its uniformity.

Then, in accordance with step c), the molding of the base material located between the conveyor belt means takes place under the influence of temperature or heat. Thus, in this step, by applying thermal energy, melting or softening of the base material or at least a part thereof is carried out, whereby, for example, granules can be formed. In this state, it can evenly fill the accommodation space formed between the conveyor means and thus form a web-shaped base that can be further processed.

The web-shaped substrate thus formed can be compressed simultaneously with step c) or after step c) according to step d). This step can be carried out in particular with a suitable press or roller. Thus, the first compression of the base in the form of a web takes place. At this stage, the substrate may already have essentially acquired the desired thickness, so that only slight compression has to be performed in the following processing steps, and thus the further steps can be carried out very gently, as will be explained in detail below. Here, in particular, it can be ensured that the temperature of the substrate is low enough to provide suitable compressibility while achieving the desired result.

In the next step e) the backing is further processed under pressure using a double belt press. At this stage, in particular, the surface properties of the substrate can be adjusted, or the thickness of the substrate can be at least substantially adjusted. To this end, the previously compressed substrate can be treated under pressure, and in particular a low pressure can be chosen such that this compression occurs only in a very small range. Thus, the design of the processing device at this stage can be selected in particular depending on the desired compression control, which can be particularly gentle and efficient.

Here, in particular, it may be preferable to use a double-belt press, since with such a press particularly gentle compression steps are possible, and in addition the surface quality or the thickness of the substrate can be adjusted and determined in a particularly efficient manner. In addition, the use of a belt press in particular enables high linear speeds, so that the entire process achieves particularly high productivity. In addition, for example, by means of pneumatic cylinders, it is possible to achieve a particularly uniform and defined adjustable belt tension of the double belt press.

In this case, smoothing or adjusting the quality of the surface at this stage may mean that although the uppermost surface is smoothed, the already introduced structures or pores are nonetheless not affected, or are only affected in a certain area, so that they are even after this stage may be present if desired. This can be achieved, in particular, by using a belt press with a suitable temperature profile and with suitable pressure values, or by means of a calender, as will be described in detail below.

In particular, when heating the base or base material in the previous steps, it may be preferred that the base is cooled during or before step e), in particular below the melting point or softening temperature of the plastic component of the base material. In other words, the substrate may be cooled before or within the double belt press. In this case, cooling can only be implemented within a limited range so that the substrate still has an elevated temperature compared to room temperature (22°C), but below the set elevated temperature, and preferably, depending on the plastic used, below the melting point or softening point of the plastic. included in the base material. In particular, by cooling the substrate, the formation of bubbles or pores can be avoided, so that the surface of the substrate can have a particularly high quality. Suitable temperatures for polyethylene, for example, are in the range below 130°C, in particular below 120°C, for example, from ≥80°C to ≤115°C, but are not limited to this.

With regard to compression of the warp in a double belt press, step e) can be realized by setting the compression ratio K1 of the warp. The compression ratio K in particular means the reduction ratio of the thickness of the substrate during the processing step. Thus, with an initial thickness of the base before processing of 5 mm and a thickness of the base after processing of 4 mm, a thickness of 80% is provided in relation to the thickness before processing, that is, the thickness is reduced by 20%. Accordingly, the compression ratio K1 is 0.2.

Exemplary compression ratios for step e) are, for example, in the range > 0, eg ≥ 0.1 to ≤ 0.3, eg ≥ 0.15 to ≤ 0.25.

The above treatment of the substrate in step e) is carried out at a temperature T1. This temperature may, for example, be in the range ≥ 150°C to ≤ 190°C, eg ≥ 160°C to ≤ 180°C, eg 170°C. Due to the fact that the base contains a plastic component, it is comparatively soft in this temperature range and can therefore be molded, in particular over its entire thickness, so that compression can be carried out particularly effectively even when using the low contact pressures of a double belt press. This step can thus serve in particular to set or calibrate the thickness of the substrate.

Optionally, in accordance with step e) above, further processing of the substrate can be carried out under pressure at a temperature T2, forming a compression ratio K2 of the substrate, where T2 < T1 and K2 < K1. In this case, the temperatures T1 and T2 refer in particular to the temperature acting on the substrate, so that it is possible that the substrate does not have the same temperature or does not necessarily have the same temperature over its entire thickness. This step therefore comprises a further pressure treatment of the base which, for example, but not limited to, can immediately follow step e). In particular, the temperature T2 is preferably controlled not simply by cooling during the treatment of the base due to lack of heat, but rather by a certain action of the appropriate tempering means, for example by active cooling using the appropriate tempering means.

The temperature T2 during step f) may allow, for example, through the use of a base, that the viscosity of the base be lower or that the base be harder than at the temperature T1 used in stage e).

This step f) can thus serve in particular not to significantly compress the substrate or reduce its thickness, but rather to adjust the surface properties of the substrate, and thus essentially to smooth the substrate or its surface.

For example, without being limited to this, compression can be performed at this stage, which can be in the range, in particular, > 0%, which, however, can be limited to values in the range ≤ 20%, and the substrate will thus subsequently have a thickness of 80% by compared to its thickness up to stage f). Thus, the compression ratio K2 is less than the compression ratio K1. Exemplary compression ratios are in the range > 0 to ≤ 0.2, such as > 0.03 to ≤ 0.15, or > 0.05 to ≤ 0.12, such as 0.1.

After the smoothing process, for example, a temperature above the crystallization temperature of the plastic can be set. In the case of linear polyethylene (LLDPE) as a base component, for example, heating to a temperature in the range of ≥ 100°C to ≤ 150°C, eg 120°C, may be sufficient and suitable. Therefore, in principle, the temperature T2 can be set in the range from ≥ 100°C to ≤ 150°C, for example 120°C.

By means of the multi-stage compression process described above, a very precise and uniform thickness can be achieved, in particular for the base materials of the panels, and in addition a particularly high surface quality can be achieved.

The post-leveling process can be carried out, for example, in a double belt press by setting a temperature gradient along the direction of transport of the substrate. Alternatively, step e) and the subsequent leveling process described above can be carried out on two separate pressing means. For this purpose, for example, an additional double-belt press or calender can be used for the post-levelling process. When, for example, a two-belt press is used, it may in particular contain a metal belt, such as, for example, the steel belt in step f) in order to achieve a suitable compression pressure even in a selected temperature range. Here, in step e), a plastic tape may suffice due to the relatively higher temperature.

In a further preferred embodiment, the substrate may be cooled between steps e) and f) to a temperature T3 where T3 < T1 and T3 < T2. In a further preferred embodiment, the substrate before or during step f) of the process may be heated to a temperature higher than the crystallization temperature of the plastic included in the substrate.

In the next step g), cooling of the web-shaped substrate is optionally carried out. The substrate can be cooled, in particular by a coolant, with defined cooling steps, to a temperature that corresponds to room temperature or, for example, does not exceed it by more than 20°C. For example, a plurality of cooling zones may be provided in order to provide certain cooling to the substrate.

In addition, the substrate may be heated after step f), in particular immediately after step f), and/or, for example, before applying additional layers, to a temperature above the crystallization temperature of one, for example, all of the plastic materials present in the base. The base can then in turn be cooled below the crystallization temperature, for example to room temperature (22°C). In particular, when the base after the base treatment after step f), and in particular after the base has been cooled after step f), is reheated to a temperature above the crystallization temperature of the plastic material included in the base material, the properties of the base can be further improved. For example, the substrate may have improved stability properties, in particular in terms of its mechanical and/or thermal and/or chemical resistance. Thus, the quality of the base can be further improved.

The crystallization temperature in the sense of the present invention is in particular the temperature to which the polymer must be heated in order to then form crystals during the cooling process. In particular, the formation of crystals begins during the cooling of the polymer at a temperature that may be below the melting point, and possibly above the glass transition temperature. Accordingly, heating to a temperature below the melting point of the respective plastic or to a temperature below the melting point may be sufficient. In the case of linear polyethylene (LLDPE), for example, heating to a temperature in the range of ≥ 100°C to ≤ 150°C, eg 120°C, may be sufficient. In the case of polypropylene, for example, heating to a temperature in the range of ≥ 160°C to ≤ 200°C, eg 180°C, may be sufficient.

Thus, as will be apparent to those skilled in the art, the duration of the appropriate heating process may depend on the speed of the substrate, its thickness and the temperature set.

After cooling the base obtained, it can first be stored as an intermediate product in the form of webs or as individual bases in the form of boards, and the process can be immediately completed. However, it is preferable that subsequent processing steps can be carried out, for example, without a grinding process, in particular to process the base to obtain a finished panel, as explained in detail below.

In order to produce the final panel, the method may comprise the following further steps to obtain a base with a decorative finish and to coat it with a protective layer. Here, the following steps are preferably carried out immediately with the fabric-shaped base produced. However, the present invention also covers the case where the web-shaped substrate is first divided into a plurality of plate-shaped substrates before one of steps g) to i) and/or the plate-shaped substrate is further processed by the respective following process steps. The following explanations refer to both alternatives respectively, with reference to the processing of the base being made for ease of understanding.

It is also possible, if appropriate, to first pre-treat the substrate against electrostatic discharge, for example before process step h), and optionally against electrostatic charge. This may in particular serve to prevent smearing during the application of the decorative finish.

According to step g), optionally, a decorative finish substrate may be applied to at least a portion of the substrate. For example, a primer, in particular for printing processes, can first be applied as a decorative finish substrate, for example with a thickness of ≥ 10 µm to ≤ 60 µm. In this case, a liquid radiation-curable mixture based on urethane or urethane acrylate can be used as a primer, optionally with one or more of a photoinitiator, active diluent, UV stabilizer, rheological agent such as a thickener, radical scavengers, leveling agent, defoamer or protective agent. , pigment and/or dye.

In addition to the use of a primer, it is possible to apply a decorative finish to a printable decorative paper, which can be provided, for example, by a resin layer as a binder previously applied to the substrate. Such a printing substrate is suitable for flexographic, offset or screen printing, and in particular for digital printing such as inkjet or laser printing. For applying the resin layer, it may be preferable to apply a resin composition which, as a resin component, includes 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 polymer composition can, for example, be applied in an amount of ≥ 5 g/m ² to ≤ 40 g/m ² , preferably ≥ 10 g/m ² to ≤ 30 g/m ² . In addition, paper or non-woven fabric with a grammage of ≥ 30 g/m ² to ≤ 80 g/m ² , preferably ≥ 40 g/m ² to ≤ 70 g/m ² , can be applied to a board-shaped substrate.

In addition, according to step h), a decorative finish that replicates the finish pattern can be applied to at least a portion of the base. In this case, the decorative finish can be applied by so-called direct printing. The term "direct printing" in the sense of the present invention means the application of a decorative finish directly to the base panel or to the non-printing layer of fibrous material applied to the base or to the substrate of the decorative finish. Various printing techniques can be used, such as flexographic, offset or screen printing. In particular, for example, inkjet or laser printing can be used as digital printing techniques.

The decorative layers can be formed, in particular, from radiation-curable paint and/or ink. For example, a UV curable ink or ink may be used.

The decorative layers can suitably be applied in thicknesses ranging from ≥ 5 µm to ≤ 10 µm.

It can also be provided that, in addition to the positive image in terms of color and/or texture, also a corresponding negative image of the trim pattern is applied. In more detail, as is known, for example, from positive staining or negative staining of wood-based materials, a color impression, for example from grain, can be reversed using digital data, so that a negative color is obtained, or in particular lighter and darker areas. . In addition to the color print, corresponding results can also be obtained for the applied structure, so that a negative can also be realized in terms of the design of the structure. Even such effects can be easily integrated based on digital 3D data and without delays or retooling in the manufacturing process.

According to step i), the protective layer may be applied to at least a portion of the decorative trim. Such a layer for protecting an applied finish can in particular be applied in a subsequent step as a wear or cover layer on top of a decorative layer which in particular protects the decorative layer from wear or damage caused by dirt, moisture or mechanical influences such as abrasion. . For example, the wearing and/or protective layer can be applied as a pre-manufactured top layer, for example based on melamine, onto the printed substrate and bonded to it by means of pressure and/or heat. In addition, it may be advantageous to also apply a radiation-curable composition, such as a radiation-curable lacquer, for example an acrylate lacquer, to form the wear and/or cover layer. The wear layer may include hard materials such as titanium nitride, titanium carbide, silicon nitride, silicon carbide, boron carbide, tungsten carbide, tantalum carbide, alumina (corundum), zirconia, or mixtures thereof, to increase the wear resistance of this layer. In this case, the application can be carried out, for example, by means of rollers, such as rubber rollers, or pouring devices.

In addition, the cover layer may first be partially vulcanized, and then a urethane acrylate finish coating process and a finish vulcanization process may be performed, for example, using a gallium emitter.

In addition, the cover and/or wear layer may include agents to reduce the static (electrostatic) charge of the final laminate. To this end, for example, the cover and/or wear layer may contain compounds such as choline chloride. The antistatic agent, for example, can be contained in a concentration of ≥ 0.1 wt.% to ≤ 40.0 wt.%, preferably from ≥ 1.0 wt.% to ≤ 30.0 wt.%, in the coating layer and/or composition to form a wear layer.

In addition, in the cover layer or in the wear or cover layer, a structuring, in particular a surface structure corresponding to the decor, can be formed by introducing pores. In this case, the base plate may already have a structure, and the alignment of the printing tool for applying decorative finishes and the base plate relative to each other is carried out depending on the structure of the base plate detected by optical methods. To align the print tool and the base plate relative to each other, the relative movement between the print tool and the base plate required for the alignment process can be performed by moving the base plate or moving the print tool. In addition, the structuring of the decorative panels can be carried out after application of the wear and/or cover layer. To this end, it may be preferable that a curable composition is applied as the cover and/or wear layer and the vulcanization process is carried out only until the cover and/or wear layer is partially cured. In such a partially vulcanized layer, the desired surface structure is obtained by embossing with suitable tools, such as a roller with a tungsten carbide structure or a punch. In this case, the embossing process is carried out in accordance with the applied decorative finish. In order to ensure sufficient conformity between the structure to be introduced and the decorative finish, the base plate and the embossing tool can be aligned relative to each other by appropriate relative movements. Once the desired structure has been introduced into the partially vulcanized cover and/or wear layer, a process for further curing the structured cover and/or wear layer is carried out.

In addition, a protective layer may be applied to the side opposite the decorative side.

The method described above enables the production of a panel with a substrate having a particularly high resistance to moisture and heat.

In another preferred embodiment, prior to step e), the release agent may be positioned such that, in at least a two belt press, it is located between the base and a conveyor means, such as an upper or lower conveyor means, preferably between the base and both conveyor means. In this embodiment, the adhesion of the substrate to the conveyor means can be prevented particularly effectively. The release agent can be, for example, wound on a first roll and fed with the substrate through a double belt press, and optionally through a subsequent press unit such as a calender, before being wound onto another roll. Preferably, there is no relative velocity between the release agent and the substrate. In other words, the release agent preferably moves at the same speed as the base. For example, the release agent may contain release paper such as oil paper. Oiled paper, also referred to as waxed paper, is known per se and means, for example, wood-free paper which contains, for example, an organic substance such as oil, wax or paraffin, for example, is impregnated with them.

According to one additional embodiment, step d) can be performed using a tension roller. By using a tensioner roller as a compression unit, the desired compression can be achieved in a certain way using simple and inexpensive means, even at high line speeds. In order to be able to set an appropriate and, depending on the desired result, a suitable force, the roller can be displaceable, for example, in a direction perpendicular to the passing base material. In this case, the tension roller may, for example, comprise only one roller, which applies force only in combination with the counter force generated by the belt tension of the conveyor means. Alternatively, one or a plurality of counter rollers may be provided which apply an appropriate counter force.

Tension roller in the sense of the present invention means a roller which is positioned so that the base passes through it in an S-shaped path, as is well known to those skilled in the art and is described in detail below with reference to the drawings.

In addition, a temperature gradient can be set as an option in the double belt press. This can be achieved in particular by means of a temperature gradient in a direction perpendicular to the transport direction. In this embodiment, a particularly high line speed can be achieved because a particularly rapid heating can be achieved, allowing such a high line speed to be obtained. Furthermore, it is possible to prevent excessively high temperatures from being applied to the base material, which can prevent damage and ensure particularly high quality. In addition, outgassing when the base material is heated can be improved and accelerated, which in turn allows a high line speed to be achieved and additionally provides a particularly large margin of stability and quality by preventing gas inclusions. In the latter case, in particular, the area below the base material may be heated to a higher temperature than the area above the base material, i.e. the lower tempering element may have a higher temperature than the upper tempering element. For example, a temperature gradient in the range of 50°C may be preferred.

With regard to additional technical features and advantages of the method described above, direct reference is made here to the above description of the base material and the panel.

The present invention is further explained below with reference to the drawings and an exemplary embodiment.

Fig. 1 schematically shows one embodiment of an apparatus for the partial production of a decorated wall or floor panel in accordance with the present invention; And

Fig. 2 shows an exemplary idler for performing a step of this method.

The device 10 shown in FIG. 1 adapted to the method of producing a decorated wall or floor panel. Here, with reference to FIG. 1 describes specific processing stations for the following stages:

a) providing a flowable base material 20, in particular a granulate,

b) placing the base material 20 between two conveyor belt means 12, 14,

c) molding the base material 20 under the influence of temperature to form the base 36 in the form of a web,

d) compression of the base 36,

e) processing the base 36 under the action of temperature and pressure, in particular using a double belt press,

f) optional base 36 cooling.

After these steps, the process may contain additional steps to obtain the final wall or floor panel.

The device 10 according to FIG. 1 primarily comprises a pair of annular conveyor belt means 12, 14, which are guided in particular by deflection rollers 16 in such a way that a receiving space 18 is formed between them for receiving and processing the provided fluid, in particular granular, base material 20. Base material 20 contains a matrix material and a solid material, wherein the matrix material is present in an amount of from ≥ 25 wt.% to ≤ 55 wt.%, in particular from ≥ 35 wt.% to ≤ 45 wt.% by weight of the base material, and moreover, the solid material is present in an amount of from ≥ 45 wt.% to ≤ 75 wt.% by weight of the base material, in particular from ≥ 55 wt.% to ≤ 65 wt.%, and the matrix material and the solid material together are present in an amount of ≥ 95 wt. .% by weight of the base material, in particular ≥ 99 wt.%, and the solid material is formed at least 50 wt.%, in particular at least 80 wt.%, in particular at least 95 wt.% from a solid composition consisting of at least pe from the first layered silicate powder and the second layered silicate powder, and the matrix material is formed of at least 50 wt.%, in particular at least 80 wt.%, in particular at least 95 wt.% of the plastic composition, consisting of a homopolymer and at least a first copolymer and a second copolymer.

In particular, the base material 20 can be provided with a kneader mixer in which the raw materials are mixed and conveyed by a screw, and thus forced through a perforated plate and cut into small particles, for example, by an angle cutter, to obtain a granulate.

The conveyor means 12, 14 may be at least partially made of polytetrafluoroethylene, for example coated with it. In addition, the conveyor means 12, 14 may, at least in part, have a roughness or structure, in particular on that side which faces the receiving space 18. In addition, the conveyor means 12, 14 may have a width in the range of approximately 1. 5 m

For applying the base material 20 between the conveyor belt means 12, 14 or in the receiving space 18, an outlet unit 22 is provided with one or more outlet heads 24, whereby the base material 20 can be placed on the lower conveyor means 14. The outlet heads 24 may comprise a tube 25 which applies the base material 20 to the respective spreading rollers 26, after which the base material 20 can be spread onto the lower conveyor means 14.

In order to ensure uniform application of the base material 20 to the lower conveyor means 14, a sensor may be provided to check the placement of the base material 20 between the two conveyor belt means 12, 14. This sensor may in particular be associated with the release unit 22 in order to immediately correct the inaccurate filling of the receiving space 18 in case of detection.

In addition, vibrators may be provided to ensure uniform distribution of the base material 20. They may, for example, act on the lower conveyor means 14, and may be located, for example, under the lower conveyor means 14 for good distribution of the base material 20.

In addition, to prevent undesirable contamination and damage to downstream processing stations, a metal detection sensor capable of detecting inadvertent metal may be provided.

In addition, a molding unit 28 is provided in the transport direction of the conveyor means 12, 14 indicated by arrow 13, the molding unit being configured to mold the base material 20 under the action of temperature or heat to melt the base material 20 while forming the base material 36 in the form of a web. . To this end, the forming unit 28 may have two plate forming means 30, 32 which can be heated by one or more heating means 34, for example by means of an oil heat base. As a result, the base material 20 can be heated until, for example, depending on the melting temperature of the base material 20 or part thereof, it reaches a temperature of ≥ 180° to ≤ 200°C. To this end, the forming unit 28 or the forming means 30, 32 can be heated, for example, to a temperature of up to 250°C. For this purpose, for example, one or a plurality of independently adjustable heating sections can be provided for setting the temperature gradient. For example, the forming means 30, 32, which may be several meters long, may be wholly heated, or only part of them may be heated.

In addition, the forming block 28 may in particular comprise a parallel gap which can be formed by the plate forming means 30, 32. In this case, however, a conical inlet may be provided at the inlet to improve the inflow of the base material 20. The force acting on the base material 20 may be > 0 kg/m ² to ≤ 1 kg/m ² . In this way, in particular, uniform pressing can be ensured without a pressure profile or pressure gradient.

On FIG. 1, it can also be seen that the lower mold means 32 is longer than the upper mold means 30 and starts earlier than the upper mold means 30. In this way, it can be achieved that the processing takes place only when the base material 20 is already melted or at least partially melted and at least partially softened. This allows you to accurately determine the molding process.

Further in the transport direction of the conveyor means 12, 14, the web-shaped base 36 passes through the pressing means 38. The pressing means 38 may, for example, include a tension roller, which is shown in detail in FIG. 2. The tension roller can move substantially perpendicular to the surface of the base 36 and thus to the direction of movement of the base 36, indicated by arrow 58, so that the required pressure can be easily adjusted. In addition, the pressing means 38 may, for example, exert pressure on the substrate 36 in the range of ≥ 1 kg/m ² to ≤ 3 kg/m ² . The tension roller includes a main roller 60 which acts on a web-shaped base 36. Here, under some circumstances, the tension of the belt may be sufficient as a counterpressure, however, it is preferable to provide at least one counterpressure roller 62. In addition, two pairs of calender rollers 64 and optional deflection rollers 66 can be provided for suitable guiding of the web-shaped base 36, which can provide a suitable web tension. On FIG. 2, it can be seen that the web-shaped base 36 is fed twice in an S-shape around the deflection rollers 66 and the main roller 60, and it is this type of trajectory that defines the term idler roller. In more detail, the web-shaped base 36 may extend about 50% or more around the main roller 60. The temperature of the substrate 36 at the inlet to the pressing means 38 corresponds in particular to the temperature at the outlet of the forming unit 28 .

From press means 38, warp 36 is then fed to additional press means 40. In order to compensate for any heat loss of warp 36, or to deliberately further heat or cool warp 36, one or more additional dispensing means 42 may be provided between press means 38, 40. .

Returning to the pressing means 40, it may preferably be a double belt press, which in particular may comprise steel belts 44, 46 which may be guided by deflection rollers 48, 50. , and/or rollers on one side of the gap may be spaced in the range of ≥ 1 m to ≤ 2 m, for example 1.5 m apart, and the tapes 44, 46 may have a width in the range of approximately 1.5 m. In accordance with FIG. 1, the base 36, located between the conveyor means 12, 14, is guided between deflection rollers 48, 50, and thus between belts 44, 46, such as, in particular, steel belts. On the side of the belts 44, 46 opposite the base 36, corresponding pressing and/or heating means 52, 54 are provided. for example, an air heater and a plurality of rollers may be provided which may provide intermittent compression. In this case, the substrate 36 may be exposed to temperatures in the range up to 250°C. For example, this temperature may be above the melting point or softening temperature of the base material or part thereof by an amount in the range from ≥ 25°C to ≤ 35°C. In addition, pressure may be applied to the substrate 36 such that the substrate 36 is compressed in step e) by a factor of ≤ 7.5%, preferably ≤ 5%, for example in the range of ≥ 0.1 mm to ≤ 0.2 mm. In this case, the pressing and/or heating means 52, 54 can essentially occupy the entire area between the deflecting rollers 48, 50, or only a limited area along the transport direction. After passing through the pressing means 40, the substrate may have a temperature in the range of 190°C.

The pressing means 40 may have a variable pressure profile, for example from 6 mm to 4.1 mm, or preferably may be configured as an isochoric press.

In the transport direction after the pressing means 40 according to FIG. 1 there is a cooling means 56 by means of which the substrate can be cooled down to a temperature, for example, in the range ≤ 35°C. Cooling means 56 may be water-cooled, for example, and may comprise a plurality of cooling zones in order to provide specific cooling through finely tuned cooling programs. The length of the cooling zone can correspond to the working length of the pressing means 40. After the coolant 56, for example, another cooling belt can be provided.

Following these process steps, the base 36, which may have a final thickness in the range of ≥ 3 mm to ≤ 5 mm, for example 4.1 mm, can be immediately further processed or stored, for example, as a base 36 in web form or as divided bases 36 in the form of plates.

After that, further steps can follow:

g) optionally applying a decorative substrate to at least a portion of the base 36,

h) applying a decorative finish reproducing a decorative pattern to at least a portion of the base 36,

i) applying a protective layer to at least a portion of the decorative trim,

j) optional structuring of the protective layer, and

k) optional treatment of the base 36 from electrostatic discharge before one of the above steps.

LIST OF REFERENCES

10 - device

12 - belt conveyor means

13 - arrow

14 - belt conveyor means

16 - deflecting roller

18 - receiving space

20 - base material

22 - release block

24 - exhaust head

25 - pipe

26 - scattering roller

28 - forming block

30 - shaping agent

32 - shaping agent

34 - heating means

36 - base in the form of a canvas

38 - pressing means

40 - pressing means

42 - release agent

44 - steel bands

46 - steel bands

48 - deflecting roller

50 - deflecting roller

52 - pressing and/or heating means

54 - pressing and/or heating means

56 - coolant

58 - arrow

60 - main roller

62 - counter pressure roller

64 - calender roller

66 - deflecting roller.

Claims (21)

1. Base material (20) for the production of a base (36) for a decorated wall or floor panel, containing a matrix material and a solid material, the matrix material being present in an amount of ≥ 25 wt. % up to ≤ 55 wt. % by weight of the base material, and the solid material is present in an amount of ≥ 45 wt. % up to ≤ 75 wt. % by weight of the base material, and while the matrix material and the solid material together are present in an amount of ≥ 95 wt. % by weight of the base material, characterized in that the solid material is formed by at least 50 wt. % by weight of a solid material from a solid composition consisting of at least a first layered silicate powder and a second layered silicate powder, and the matrix material is formed by at least 50 wt. % by weight of a matrix material from a plastic composition consisting of a homopolymer and at least a first copolymer and a second copolymer, wherein the first particulate layered silicate powder has a size D ₅₀ smaller than the D ₅₀ size of the second layered silicate powder, while the melt flow rate of the first copolymer is less than the second copolymer and homopolymer, and the melt flow rate of the second copolymer is less than the homopolymer and greater than the first copolymer, while in addition to the solid material and the matrix material, additional substances are present in the base material in an amount of < 5 wt. % by weight of the base material. 2. The base material according to claim 1, characterized in that the first layered silicate powder and/or the second layered silicate powder contain talc. 3. Base material according to any one of the preceding claims, characterized in that the solid composition contains the first layered silicate powder in an amount of ≥ 35 wt. % up to ≤ 85 wt. % by weight of the solid composition, in the form of particles having a size D ₅₀ in the range from ≥ 3 μm to ≤ 6 μm, and having a size D ₉₈ in the range from ≥ 10 μm to ≤ 30 μm, and also contains a second layered silicate powder in an amount of ≥ 15 wt. % up to ≤ 65 wt. % by weight of the solid composition, in the form of particles having a size D ₅₀ in the range from ≥ 6 μm to ≤ 10 μm, and having a size D ₉₈ in the range from ≥ 20 μm to ≤ 40 μm. 4. Base material according to any one of the preceding claims, characterized in that the homopolymer, the first copolymer and the second copolymer contain polypropylene. 5. Base material according to any one of the preceding claims, characterized in that the first copolymer comprises a heterophasic polypropylene and the second copolymer comprises an ethylene-propylene copolymer and isotactic polypropylene. 6. The base material according to any one of the preceding paragraphs, characterized in that the second copolymer contains ethylene in an amount of ≥ 8 wt. % up to ≤ 22 wt. %. 7. A base material according to any one of the preceding claims, characterized in that the melt flow rate of the homopolymer is greater than the melt flow rate of the first copolymer and the second copolymer. 8. A base material according to any one of the preceding claims, characterized in that the melt flow rate of the second copolymer is greater than the melt flow rate of the first copolymer. 9. The base material according to any one of the preceding paragraphs, characterized in that the homopolymer is present in an amount of ≥ 10 wt. % up to ≤ 40 wt. % by weight of the plastic composition, and/or that the first copolymer is present in an amount of ≥ 40 wt. % up to ≤ 70 wt. % by weight of the plastic composition, and/or that the second copolymer is present in an amount of ≥ 10 wt. % up to ≤ 40 wt. % by weight of the plastic composition. 10. Base material according to any one of the preceding claims, characterized in that the matrix material contains at least one color additive in addition to the plastic composition. 11. Base material according to claim 10, characterized in that the coloring additive is a pigment composition based on thermoplastic base materials, which has heat resistance up to at least 230°C. 12. A base material according to any one of the preceding claims, characterized in that the matrix material comprises polyethylene in the form of low density polyethylene LDPE. 13. A base material according to any one of the preceding claims, characterized in that the solid material contains at least one additional solid in addition to the solid composition. 14. The base material according to claim 13, characterized in that the additional solid has a bulk density in the range ≤ 2000 kg/m ³ and / or that the additional solid is selected from the group consisting of wood, expanded clay, tuff, pumice, cellular concrete, inorganic foam and cellulose. 15. Decorated panel, in particular a decorated wall or floor panel, containing a base (36) and a decorative finish applied to the base, while, in particular, a protective layer provided with a structure is applied to the decorative finish, characterized in that the base (36) contains the base material (20) according to any one of the preceding paragraphs.

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