WO2007003805A2 - Floor covering strips or slabs, production method thereof and production facility used for same - Google Patents

Floor covering strips or slabs, production method thereof and production facility used for same Download PDF

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Publication number
WO2007003805A2
WO2007003805A2 PCT/FR2006/050428 FR2006050428W WO2007003805A2 WO 2007003805 A2 WO2007003805 A2 WO 2007003805A2 FR 2006050428 W FR2006050428 W FR 2006050428W WO 2007003805 A2 WO2007003805 A2 WO 2007003805A2
Authority
WO
WIPO (PCT)
Prior art keywords
panels
slabs
characterized
method according
decorative
Prior art date
Application number
PCT/FR2006/050428
Other languages
French (fr)
Other versions
WO2007003805A3 (en
Inventor
Thierry Miclo
Jean-Jacques Strub
Claude Campo
Original Assignee
ESPACE PRODUCTION INTERNATIONAL EPI, Société Anonyme
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority to FR0551206A priority Critical patent/FR2885626A1/en
Priority to FR0551206 priority
Priority to FR0552160A priority patent/FR2885628B1/en
Priority to FR0552160 priority
Application filed by ESPACE PRODUCTION INTERNATIONAL EPI, Société Anonyme filed Critical ESPACE PRODUCTION INTERNATIONAL EPI, Société Anonyme
Priority claimed from US11/913,949 external-priority patent/US20080168742A1/en
Publication of WO2007003805A2 publication Critical patent/WO2007003805A2/en
Publication of WO2007003805A3 publication Critical patent/WO2007003805A3/en

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Classifications

    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04FFINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00Flooring
    • E04F15/02Flooring or floor layers composed of a number of similar elements

Abstract

The invention relates to a method of producing floor covering strips or slabs (1) comprising support panels (2) which are covered with a decorative layer (3) by means of surfacing. The invention is characterised in that it comprises the following steps consisting in: applying glue to all or part of at least one face (5) of a support panel (2), applying a decorative sheet (7) to the glued face (5) of the support panel (2), in particular by means of calendering; and cutting the panel (2) into floor covering strips and/or slabs (1). The invention also relates to a facility that is used to implement said method and to a floor covering strip thus produced.

Description


  [0001] FLOORS OR SLABS OF FLOORING AND METHOD AND INSTALLATION FOR MANUFACTURING THESE BLADES OR SLABS.

The invention relates to a method of manufacturing slats or floor tiles from support panels coated by surfacing a decorative layer. The invention also relates to an installation for carrying out the method, as well as a floor covering composed of blades or slabs resulting from such a process.

In the context of the state of the art, represented for example by the document US-2004/0045940, it is more particularly known floor coverings, said laminated, composed of a plurality of blades that the it is assembled by gluing or mechanical interlocking.

These blades are cut from laminated panels coated on the upper face of a decorative layer.

[0005] In this regard,

   such panels comprise a core of wood or wood-based, for example of HDF or MDF type, that is to say formed from pressed wood fibers in press and by addition of a binder such as a resin. This core of the panel can still be made of synthetic material, or even from recycled materials.

Furthermore, this core of a laminated panel receives, on its upper face, a decorative coating consisting of a printed sheet of a decor and impregnated with a polymerizable resin, for example melamine or other type. Similarly, on this decorative coating is applied an overlay in the form of a cellulosic sheet impregnated with resin and containing a charge, of the alumina oxide type, which has the particularity of giving the floor covering a better resistance to abrasion.

   On the underside of such laminated panels is applied a layer, called balance, to balance constraints in the panel. It consists, usually, in a simple sheet of kraft paper, also impregnated with resin.

These various layers composing a laminated panel: overlay, decorative coating, core and balance; are hot pressed to bind them together.

   Also, it is necessary to cool the panels before machining them to cut the blades or slabs for making the floor covering.

Thus, at the output of the press, these melamine panels are at a temperature of the order of 100 <0> C and for cooling they are stored until their temperature stabilizes which can take a some time, especially when these panels are stored by stacking immediately after the pressing operation.

However, precisely, such cooling over a prolonged period may cause constraints at these panels, as is explained in particular in EP-O.978.359.

   Furthermore, the longer the stabilization time of the panels, the more it is necessary to have large storage spaces resulting in flexibility and responsiveness of less production.

It should also be noted that such storage spaces are necessarily controlled environment enclosures requiring special equipment which further increases the cost of the area devoted to the panels being cooled.

To this must be added that the hot pressing operation itself poses a number of problems. In particular, as explained above, the core of the panel can be made from fibers or particles, including wood or other materials, agglomerated with a synthetic binder.

   Under the effect of heat, such materials can behave differently. In particular, it can result in deformations resulting in tiling or banana effects of the blades making up the flooring.

In addition, it necessarily results in differential expansion phenomena between the materials that are very difficult to manage and from which stems, precisely, the need to submit the panels to a period of prolonged stabilization at the end.

Similarly, during the impregnation of the melamine paper it undergoes an expansion compensated under the effect of heat, which, depending on the type of printed decoration, may disturb the decorative appearance of the flooring that we want to get.

[0014] Moreover,

   it will be appreciated that the levels of gloss that can be achieved for a laminate floor are limited. This degree of brightness results, as the relief effects, sheets that dress the press. Thus, whenever it is desired to change the degree of gloss of the panels manufactured it is necessary to replace the sheet intended to come into contact with the upper face of these panels, knowing, moreover, that such sheets are subject to wear and they should be replaced or retreated periodically.

As mentioned above, the sheet that dresses a press also results in the desired relief effects.

   In particular, some laminate flooring has, as a decorative coating, an imitation of tile, requiring a difference in relief and appearance between the tiles and the joints defining the latter. The difficulties in obtaining these different surface conditions, combined with the phenomenon of expansion of the melamine-decor paper, leads to panel manufacture with a high rejection rate.

The present invention proposes to provide a solution to all of the above problems.

   For this, it was necessary, in a first inventive step, to go against a prejudice of the skilled person according to which only the laminating solution provides a floor covering of an outfit sufficient mechanical for such an application.

The solution according to the invention results, moreover, a complete questioning of the manufacturing process of this type of laminate flooring. In particular, it was in the context of a second inventive step that a solution was sought that avoided any heat input when surfacing the panels.

   In particular, according to the method according to the invention, a panel coated with a decorative layer can be immediately machined for the manufacture of flooring boards.

Advantageously, the method according to the invention makes it possible to design an installation for its implementation comprising, immediately downstream, a panel production unit, a cutting and machining unit for debiting these panels with slats or slabs. floor coverings.

The advantages of the method according to the invention consist in that it is possible to obtain perfectly stable flooring blades, having no risk of deformation resulting from internal tensions following surfacing operations. panels from which these blades are derived.

[0020] Moreover,

   the method according to the invention avoids any intermediate storage for stabilization of the panels or any cooling unit.

Another advantage of the present invention is that the core of a panel can be made of any type of material, including materials not resistant to temperatures as high as those used in a usual lamination process.

   In addition, insofar as, for the application of the decorative coating, conventional coating techniques, such as calendering, are used, the support panels are not necessarily subjected to such high pressures which could limit, until now, the nature of the materials composing the soul of these panels.

Thus, the invention relates to a method of manufacturing slats or flooring slabs from support panels coated by surfacing a decorative layer, characterized in that:

We stick all or part at least one side of a support panel;

Is applied, including calendering, a decorative sheet on said bonded side of the support panel;

  

Said panel is debited slats and / or slabs flooring.

According to the invention, all or part of each of the faces of the support panel are glued for application, in particular by calendering, on one of the faces of a decorative sheet and, on the opposite face, of a balance.

[0027] In particular, according to the invention, at least one of the faces of the support panel, more particularly the face intended to receive the decorative sheet, is bonded with a urea-formaldehyde glue.

According to another feature of the invention, the decorative sheet is coated on its decorative face with at least one lacquer layer containing a charge of alumina oxide.

   As for the installation for implementing the method according to the invention, it comprises a panel surfacing unit and a cutting and machining unit for discharging said panels into slab surfaces and / or floor covering slabs, and means for transferring the panels between said surfacing unit and the cutting and machining unit.

The present invention will be better understood on reading the following description relating to an exemplary embodiment and referring to the accompanying drawing in which:

[0030] "Figure 1 is a schematic representation in section of a flooring plate according to the invention;

  

[0031] "and Figure 2 schematically illustrates the method of manufacturing such a blade.

As shown in Figure 1, the present invention relates to the field of floor coverings. Such a floor covering is composed of blades 1 or slabs from panels 2 (visible in the diagram of FIG. 2) coated by surfacing a decorative layer 3.

It should be noted that in the following description the term "blade" is used generically, insofar as if such a blade has been illustrated rectangular in Figure 1, it could still be of shape square to be more like a slab.

To return to the panel 2 from which these blades 1 are cut, it comprises a core 4 which can be made of various materials.

   In particular, this core 4 can be based on wood, especially HDF, MDF or chipboard, just as it can be made of a synthetic material, or even based on recycled materials. As for the decorative layer 3 that receives this panel 2 on its upper face 5, it is advantageously made of a printed decor sheet.

   Note that at its lower face 6, this panel 2 can receive a layer of a balancing coating, often called balance or a layer of acoustic insulation material.

Ultimately, according to the process according to the invention, the decorative sheet 7 is applied to the blade 4 of the panel 2 by gluing, more particularly using a urea-formaldehyde glue 8.

Thus, in a surfacing unit S, it comes to glue, by suitable means, all or part of the upper face 5 of the panel 2 before applying, including calendering, the decor sheet 7.

According to the invention,

   it is previously coated on its decorative face 9 with at least one layer of a lacquer comprising a filler intended to improve the resistance to abrasion of the floor covering that are constituted by the blades 1 resulting from the process according to the invention .

Advantageously, this charge corresponds to alumina oxide.

Also just as advantageously, this lacquer which is coated with the decor sheet 7 defines the degree of gloss that it is desired to obtain.

[0040] Thus, because of the variety of existing lacquers, it is possible to obtain a significant diversity of aspects and degrees of gloss. In addition, this solution makes it possible to overcome the problems of paper expansion.

   If necessary, simultaneously or as part of a separate step, the underside of a panel 2, may also be glued, including a urea-formaldehyde glue, to receive the layer of a coating of balancing or balance 10. This can be defined, substantially, by a sheet of craft paper.

Furthermore, as a replacement or in addition to the balance 10, on the underside 6 of the support panels 2 may be applied a layer of a sound insulating material.

   This has not been shown in the figures of the drawing.

According to the invention, the panels 2 leaving the surfacing unit S, in particular coated with their decorative layer 3, are directly routed, by transfer means 13 adapted, towards a cutting unit and machining 11 where they are cut into blades 1 floor covering.

In other words, at the output of this cutting and machining unit 11 blades 1 comprise peripheral edge, interlocking means, tongue and groove type, allowing their assembly by gluing or mechanical connection.

[0044] Note, however,

   downstream of this cutting and machining unit 11 can be implanted a unit for applying an acoustic insulation coating on the underside of these blades 1 in case the panels have not been equipped upstream.

The blades thus obtained through the process according to the invention meet all the criteria which must satisfy a floor covering. In particular, the addition of a filler, of the alumina oxide type, in the lacquer of which the decorative sheet is previously coated, gives the blades a perfect resistance to abrasion, without it being necessary to use the usual stratification solution.

   But more particularly, the application by gluing, more particularly using a urea-formaldehyde glue, the decorative sheet on the panel leads to a polymerization without heat input, requiring no stabilization phase and allowing the treatment of the panel directly in the cutting and machining unit for the manufacture of the blades. Intermediate storage is not necessary, except for flexibility of operation, means 12 for forming a buffer stock can be provided between the surfacing unit S of the panels 2 and the cutting unit. machining 11, at the level of the transfer means 13.

   In particular, such a buffer stock 12, illustrated in broken lines in FIG. 2, makes it possible, for example, to change the decor sheet 7 at the level of the surfacing unit S, without it being necessary to interrupting the operation of the cutting unit 11.

Similarly, a stoppage of the latter allows, through the constitution of the buffer stock 12 to stop the surfacing unit S panels 2.

Finally, avoiding, throughout the production of blades or slabs flooring to subject the materials to significant temperature variations, it comes to overcome all the drawbacks that usually result.

In particular,

   any phenomenon of expansion of the decorative sheet is avoided as the birth of tensions in the material constituting the core of the panels.

In this respect, the method according to the invention makes it possible to use a greater diversity of material composing this soul of the panels in comparison with those exploitable by adopting a solution of a hot pressing.

   In particular, synthetic materials that are sensitive to heat can be used, just like materials capable of withstanding only a low compression load, knowing that by calendering, the panels are subjected to pressures often lower than under a press melamine for example.

Obviously, being exempted from storing the panels at the output of surfacing unit S, we gain production space.

Thus, as apparent from the foregoing description, the present invention represents a clear progress in the field of making floor covering.

Claims

claims
Process for the production of flooring slabs or slabs (1) from support panels (2) coated with a decorative layer (3), characterized in that:
at least one face (5) of a support panel (2) is fully or partially adhered;
a decorative sheet (7) is applied, in particular by calendering, to said bonded surface (5) of the support panel (2);
said panel (2) is cut into slats and / or slabs (1) of flooring.
2. Method according to claim 1, characterized in that it glues all or part of each side (5, 6) of the support panel (2) for the application, including calendering, a decorative sheet (7) on one (5) of the faces and, on the opposite face (6), a layer of a balancing coating (10).
3. Method according to any one of the preceding claims, characterized in that urea-formaldehyde glue is used for sizing at least the faces (5, 6) of the support panel (2), plus particularly, the face (5) intended to receive the decorative sheet (7).
4. Method according to any one of the preceding claims, characterized in that the decorative sheet (7) is coated on its decorative face (9) with at least one lacquer layer containing a defined filler capable of improving the resistance to abrasion of the floor covering.
5. Method according to any one of the preceding claims, characterized in that a buffer stock (12) is formed between a surfacing unit S of the panels and a cutting and machining unit (11) for debiting these panels (2) of slats or slabs (1) of flooring.
6. Method according to any one of the preceding claims, characterized in that on the opposite side (6) to the decorative layer (3) is applied to the panels (2) a layer of acoustic insulation material.
7. Method according to any one of claims 1 to 5, characterized in that it is applied on the underside of the slabs or slabs (1) cut from the panels (2), a layer of a material sound insulation.
8. Installation for carrying out the method according to any one of the preceding claims, characterized in that it comprises a panel surfacing unit (S) (2) and a cutting and machining unit (11). ) for feeding said panels (2) slab surfaces and / or slabs (1) of flooring, and means for transferring (13) the panels (2) between said surfacing unit (S) and the cutting and machining (11).
9. Installation according to claim 8, characterized in that it comprises means (12) for constituting a buffer stock of panels (2) at the transfer means (13) between the surfacing unit (S) of panels (2) and the cutting and machining unit (11).
10. Blade or slab of flooring resulting from process according to any one of claims 1 to 7, characterized in that it is provided on the upper face by gluing with a urea-formaldehyde glue, a decorative sheet (7) coated at its decorative face (9) with at least one layer of lacquer incorporating a filler, such as alumina oxide, to improve its resistance to abrasion.
PCT/FR2006/050428 2005-05-10 2006-05-10 Floor covering strips or slabs, production method thereof and production facility used for same WO2007003805A2 (en)

Priority Applications (4)

Application Number Priority Date Filing Date Title
FR0551206A FR2885626A1 (en) 2005-05-10 2005-05-10 Strip/slab fabricating method for flooring, involves pasting entire or part of side of support panel, applying decorative sheet by calandering on side, and arranging safety block for delivering panel in strips and/or slabs of flooring
FR0551206 2005-05-10
FR0552160A FR2885628B1 (en) 2005-05-10 2005-07-12 Flooring blades or slabs and method and installation for manufacturing these blades or slabs
FR0552160 2005-07-12

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US11/913,949 US20080168742A1 (en) 2005-05-10 2006-05-10 Floor Covering Strips Or Slabs, Production Method Thereof And Production Facility Used For Same
EP20060794413 EP1896271A2 (en) 2005-05-10 2006-05-10 Floor covering strips or slabs, production method thereof and production facility used for same

Publications (2)

Publication Number Publication Date
WO2007003805A2 true WO2007003805A2 (en) 2007-01-11
WO2007003805A3 WO2007003805A3 (en) 2007-04-05

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PCT/FR2006/050428 WO2007003805A2 (en) 2005-05-10 2006-05-10 Floor covering strips or slabs, production method thereof and production facility used for same

Country Status (2)

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EP (1) EP1896271A2 (en)
WO (1) WO2007003805A2 (en)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US8051886B2 (en) 2009-12-14 2011-11-08 Unilin Flooring Nc Llc Distressing process and apparatus for applying such process

Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE4107151A1 (en) * 1991-03-06 1992-09-10 Alkor Gmbh Flooring elements, e.g. board, blocks, parquet, etc. - covered with multilayer film comprising clear polyolefin top layer, adhesive interlayer(s) and filled polyolefin base layer
WO1993001378A1 (en) * 1991-07-02 1993-01-21 Perstorp Flooring Ab Pattern sheets
US20020007909A1 (en) * 2000-07-11 2002-01-24 Laurence Mott Process for the manufacturing of an improved decorative laminate and a decorative laminate obtained by the process
US20030136494A1 (en) * 2001-01-22 2003-07-24 Ulrich Windmoller Floor plank and method of manufacturing it
EP1367194A2 (en) * 2002-05-31 2003-12-03 Kronotec Ag Flooring panel and method of laying such a panel
US20040045240A1 (en) * 2002-09-10 2004-03-11 Mcilvaine Bruce L. Laminate flooring with custom images
US20040140151A1 (en) * 2003-01-09 2004-07-22 F C & C Sound suppressing flooring and method of manufacturing same

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE4107151A1 (en) * 1991-03-06 1992-09-10 Alkor Gmbh Flooring elements, e.g. board, blocks, parquet, etc. - covered with multilayer film comprising clear polyolefin top layer, adhesive interlayer(s) and filled polyolefin base layer
WO1993001378A1 (en) * 1991-07-02 1993-01-21 Perstorp Flooring Ab Pattern sheets
US20020007909A1 (en) * 2000-07-11 2002-01-24 Laurence Mott Process for the manufacturing of an improved decorative laminate and a decorative laminate obtained by the process
US20030136494A1 (en) * 2001-01-22 2003-07-24 Ulrich Windmoller Floor plank and method of manufacturing it
EP1367194A2 (en) * 2002-05-31 2003-12-03 Kronotec Ag Flooring panel and method of laying such a panel
US20040045240A1 (en) * 2002-09-10 2004-03-11 Mcilvaine Bruce L. Laminate flooring with custom images
US20040140151A1 (en) * 2003-01-09 2004-07-22 F C & C Sound suppressing flooring and method of manufacturing same

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US8051886B2 (en) 2009-12-14 2011-11-08 Unilin Flooring Nc Llc Distressing process and apparatus for applying such process

Also Published As

Publication number Publication date
EP1896271A2 (en) 2008-03-12
WO2007003805A3 (en) 2007-04-05

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