Plate-shaped building element and method for producing plate-shaped building elements

Abstract

The invention relates to a panel-shaped building element (1), in particular a floor panel, and a method for manufacturing such building elements (1). The building element (1) has a carrier panel (8) and a top surface wear layer (13). According to the invention, the carrier panel (8) is made from a multi-layer panel (2) from a second-hand product. A multi-layer panel (2) from a second-hand product can be a used laminate flooring element. It can also be B-grade goods or multi-layer panels from overproduction or discontinued collections. The multi-layer panels (2) from a second-hand product are collected and sorted and used to manufacture carrier panels (8) for panel-shaped building elements (1). For this purpose, the multi-layer panels (2) are trimmed at the edges. The wear layer (13) is applied to a top surface (11) of the carrier panel (8) manufactured from the multi-layer panel (2). A counter-layer (14) can also be applied to the underside.The side edges (15, 16) of the carrier plate (8) are profiled and connecting elements (17, 18) are formed on the side edges (15, 16).

Description

[0001] The invention relates to a plate-shaped building element, in particular a floor panel, which has a carrier plate and a top surface layer, and to a method for manufacturing plate-shaped building elements.

[0002] Surface coverings, such as floor coverings, are available in a wide variety of designs. Laminate flooring panels are widely used. These consist of a multi-layered panel with a core board made of compressed fibers. A multi-layered decorative layer is applied to the top of the core board. This decorative layer may include a resin-impregnated decorative paper and determines the appearance of the laminate. The so-called overlay or sealant is a specially resin-impregnated wear layer that gives the floor panel a high degree of surface durability. A backing layer is applied to the underside of the core board. This provides dimensional stability and moisture protection.

[0003] Laminate flooring typically consists of several rows of rectangular floor panels. Each panel has continuous grooves along one long side and one end, and continuous tongues on the opposite long and end, respectively, which are aligned with the grooves. The flooring elements are installed by connecting the tongue and groove. Today, most floor panels are connected using a click system. This system uses mechanical fasteners on the grooves and tongues that engage with adjacent panels in a floor covering, creating a snap-fit ​​connection. This allows for glue-free installation of the floor panels and also prevents gaps from forming in the installed surface due to expansion and contraction.

[0004] Sooner or later, surface coverings need to be replaced, whether due to wear and tear or renovation. This raises the question of how to dispose of these coverings, especially floor coverings like laminate. Recycling is generally straightforward if the building components are wood-based and free of chloride or PVC. Modern technical processes make it possible to recycle laminate flooring. The laminate is broken down into wood fibers and chips, which are then reintroduced into the manufacturing process. This is particularly beneficial from an ecological perspective. Laminate thus contributes to the development of a more circular economy. In the future, however, even more extensive reuse and recycling of sheet-like building components, especially laminate, is desirable.

[0005] The invention is based on the objective of creating an ecologically advantageous plate-shaped building element and of demonstrating a method for manufacturing such building elements.

[0006] Claim 1 demonstrates the solution to the present part of the problem.

[0007] The method according to the invention is the subject of claim 11.

[0008] A plate-shaped building element according to the invention is in particular a floor panel. The building element has a carrier plate and a top surface layer.

[0009] According to the invention, the carrier panel is made from a multi-layer panel of secondary use. A multi-layer panel of secondary use can be a used or previously used building component, in particular a laminate flooring element. A multi-layer panel of secondary use can also be B-grade or second-choice material. Multi-layer panels from overproduction or discontinued collections can also be used for secondary use according to the invention and for manufacturing the carrier panel of a building component according to the invention.

[0010] The invention enables the reuse of multi-layer panels, allowing for the creation of new products from old, used, or damaged panels, as well as from overproduction or discontinued collections. This reduces waste and protects the environment. The invention creates an ecologically advantageous, panel-shaped building element with sustainable and economic added value for manufacturers and consumers.

[0011] The carrier board can consist of a laminate flooring element, a wood-based material, a polymeric plastic material or a mineral mixture.

[0012] The top surface of the multi-layer panel features a decorative layer, which is specifically composed of multiple layers. The underside of the multi-layer panel has a backing layer. This repurposed multi-layer panel is processed into a substrate panel. During this process, both the top and bottom surfaces can be mechanically treated, particularly cleaned. The decorative layer on the top surface and the backing layer on the underside can also be partially or completely mechanically treated and removed.

[0013] The processing of the multi-layer panel into a substrate panel involves, in particular, trimming the edges of the multi-layer panel. This process removes the original fasteners along the side edges of the multi-layer panel.

[0014] Following the cutting or sawing process, the components are cleaned. In particular, the top and bottom surfaces can be cleaned with a brush station if necessary and then dried. Cleaning agents with antibacterial additives or fragrances can also be applied to the panels.

[0015] After cleaning and further processing or preparation, in particular by applying an adhesion promoter or primer to one side of the substrate, a wear layer is applied to the top surface. The previous used product, i.e., the multi-layer panels from a second-life application, forms the substrate for a new panel-shaped building element. For this purpose, the substrate is recoated or encased on at least one side. This is done on systems that perform panel lamination or coating. This can be achieved using PUR adhesives, PUR hot melt, permanent adhesives, reactive adhesives, especially two-component adhesives, or water-based or aqueous adhesives that cure by IR drying or hot pressing. Depending on the adhesive system used, prior application of an adhesion promoter, especially an adhesion primer, to the existing surface to be coated is advisable.

[0016] The lamination of the layers of the plate-shaped component according to the invention, in particular the carrier plate and the wear layer and optionally the backing layer, can be carried out by wet lamination, dry lamination or thermal lamination. Individual plate-shaped components can be laminated one after the other or several plate-shaped components can be laminated simultaneously.

[0017] Laminate flooring or laminate flooring elements usually have more or less pronounced textures on their top surface. These can potentially be disadvantageous in terms of adhesion and / or concealment of the new wear layer. The surface textures can also show through on the top surface. Therefore, it is advantageous to apply the wear layer to the original underside of the multi-layer panel. Unlike the old, good side, the original underside is usually smooth and less likely to be covered with adhesive residue or dirt.

[0018] The wear layer can have different structures. In particular, the wear layer is multi-layered. Films, especially decorative films, but also real wood veneers and similar materials can be used to form the wear layer. Preferably, however, films and adhesives are used that do not exert tensile stress on the product and do not affect the flatness of the flooring element. For sustainability reasons, PVC-free systems are particularly suitable. Since a laminate floor is manufactured with a backing layer and decorative layer to be very dimensionally stable, the decorative recoating to form the wear layer of the flooring element can only be applied to one side. The original decorative layer can then serve as a backing layer.

[0019] One particularly advantageous embodiment provides that the carrier plate is provided with a counter-tension on its underside.

[0020] In a subsequent processing step, the carrier plate is profiled along at least two opposing parallel side edges, with connecting elements being formed on the side edges.

[0021] The original underside of the multi-layer panel is particularly advantageous when used as the top surface of the substrate. This is especially beneficial because the original underside is typically very smooth and, if at all, subject to minimal wear during use. The original underside requires only minimal processing to function as the top surface of the substrate for the building component.

[0022] The wear layer of the plate-shaped component according to the invention is preferably multi-layered. It comprises one or more decorative layers, in particular a decorative paper or a decorative film, as well as an overlay or a sealant that gives the component high surface durability. A backing layer is applied to the underside of the carrier plate. This serves to ensure dimensional stability and moisture resistance. Depending on the embodiment, impact sound insulation can be provided on the underside of the carrier plate.

[0023] Fasteners are provided at the side edges of the carrier plate. These fasteners are preferably designed with click or snap-fit ​​elements.

[0024] The wear layer may have a decorative film. Such a decorative film preferably consists of polyethylene terephthalate (PET), polypropylene (PP) or polyolefin (PO) and is printed on at least one side.

[0025] Laminate flooring, in particular, is very well suited for reuse as a multi-layer panel. These laminate flooring elements have a closed surface, are robust and solvent-resistant, abrasion-resistant, and also flame-retardant. A key advantage is that laminate flooring largely shares the same construction, regardless of the manufacturer. The decorative layer typically consists of a melamine paper overlay with base components and a decorative paper layer. The core board is made of a high-density fiberboard. The underside of the multi-layer panels has a backing layer. Product thicknesses are consistently between 6 mm and 10 mm in certain increments. Laminate flooring elements are equipped with a click-lock system and are installed as a floating floor. At the end of their service life, these planks or laminate flooring elements can be easily removed and returned to the manufacturer or reused.The dimensions are also largely the same across manufacturers. A typical and frequently used format has a width between 192 mm and 197 mm and a length between 1280 mm and 1380 mm. Tile formats with dimensions of 300 mm x 400 mm or 400 mm x 850 mm are also available. Long plank formats have a width between 195 mm and 250 mm and a length of 1850 mm to 2200 mm. Of course, other dimensions exist as well. These can also be used as multi-layer panels for reuse. The reused multi-layer panels are collected, sorted, and categorized by size. The edges are then trimmed. This involves cutting off the existing connectors on all sides of the long edges and the ends of the multi-layer panels.

[0026] For this purpose, the multi-layer panels are fed into a sawing unit. In the sawing unit, the edges are trimmed, cutting the multi-layer panels to a uniform length and width. This trimming process preferably brings the multi-layer panels to a uniform size smaller than the smallest dimension of the existing planks or the original dimensions of the multi-layer panels from a second-use project, in order to achieve the highest possible material yield. The existing fasteners or click profiles are removed from all sides.

[0027] Afterwards, cleaning takes place. Cleaning could also be done beforehand. However, cleaning after the pruning process is advisable to remove cutting dust and similar debris.

[0028] The cleaning process may also involve mechanical action on one or both surfaces of the multi-layer panels. This can include sanding or brushing, and in particular, roughening the surfaces. Roughening the surfaces is advantageous to ensure good adhesion for subsequent bonding.

[0029] After the multi-layer panel has been processed into a substrate, the wear layer is applied to the top surface of the substrate. An adhesion promoter can be applied to the top surface for this purpose. The wear layer, which is typically multi-layered and includes a decorative paper and / or foil, is then built up. A wear-resistant coating and / or a lacquer finish forms the outermost wear layer of the wear layer.

[0030] The wear layer of the plate-shaped component according to the invention can also be a veneer layer made of real wood or a cork layer. The wear layer can be single-layered or multi-layered. An abrasion-resistant, transparent wear layer forms the surface of the wear layer.

[0031] Any material suitable for floors or walls can be used as a surface layer, provided it can be applied and bonded to a substrate made of a multi-layer panel from a repurposed building material using a bonding agent. This allows for consideration of current interior design trends and styles.

[0032] An advantageous aspect of the invention provides that the underside of the multilayer panel is used as the top surface of the carrier plate of the plate-shaped building element according to the invention. For this purpose, the multilayer panel or the carrier plate processed from the multilayer panel is turned over during the manufacturing process, and the original underside of the multilayer panel is used to construct the top surface layer of the building element.

[0033] Optionally, the multi-layer panel (reused) or the substrate made from the multi-layer panel can be treated with a disinfectant, particularly on all sides, and / or an odorant can be applied to the multi-layer panel (reused) or the substrate. Odorants can be sprayed on, for example, or added as a component to the adhesion promoter, adhesive, or primer.

[0034] The invention enables the reuse of multi-layer panels from a second-hand application. Worn or no longer needed multi-layer panels are given an attractive, modern, contemporary surface finish. Waste is avoided, resources are saved, and both ecological and economic advantages result.

[0035] One aspect of the invention provides that the plate-shaped components are provided with a marking, in particular a marking on the underside, from which the characteristic properties of a plate-shaped component can be derived, in particular that it is a plate-shaped component from a second-life use. The marking makes it clear that the plate-shaped component is a second-life (2nd) product.

[0036] The invention is described in more detail below with reference to the drawings.

[0037] The Figures 1 to 8The figures show, in a technically schematic form, a system for the reuse of multi-layer panels from a secondary use and a method for the production of a plate-shaped building element according to the invention in the form of a floor panel.

[0038] The drawings are not to scale or proportionate.

[0039] A plate-shaped building element 1 in the form of a floor panel is technically schematically represented in the Figure 8 depicted.

[0040] To manufacture a panel-shaped building element 1, multi-layer panels 2 from a secondary use are collected. The multi-layer panels 2 used can be used products, as well as B-grade goods or multi-layer panels 2 from overproduction or discontinued collections. An unsorted number of multi-layer panels 2 in different dimensions and sizes are in the Figure 1 depicted.

[0041] Such a multi-layer panel 2 is, in particular, a laminate flooring element. The multi-layer panel 2 has a core 3 made of a compressed, in particular high-density, wood-based fiber material, as well as a decorative layer 4 on the top side and a backing layer 5 on the bottom side (see [reference]). Figure 4 The multi-layer panel 2 has a top surface 6 and a bottom surface 7.

[0042] The multi-layer panels 2 from a second-hand use are sorted and categorized by size ( Figure 2 The multi-layer panels undergo a quality inspection (2). This inspection focuses particularly on flatness, technical properties, and the degree of soiling. Furthermore, the panels are sorted according to material thickness.

[0043] The multi-layer panels 2 from second-life use are assessed for their suitability for use as a carrier panel 8 of a plate-shaped building element 1. Unusable multi-layer panels 2 are sorted out and sent for other recycling.

[0044] Sorted by size ( Figure 3 The multi-layer panels 2 are then fed into a processing unit for the carrier board 8. During processing, the edges of the multi-layer panels 2 are trimmed. This is done in a sawing unit as described in the Figure 4 This is shown schematically. When trimming the edges of the multi-layer panels 2, the old fasteners 9, 10 are separated from the multi-layer panels 2. This is shown in the Figure 4 depicted.

[0045] The refurbished multi-layer panels 2 or the carrier boards 8 manufactured from them are cleaned. Surface treatment may be carried out during this process.

[0046] A carrier plate 8 is in the Figure 6 The carrier plate 8 still exhibits the original multi-layered structure of the multi-layered panel 2 with the panel body 3, the decorative layer 4 and the counter-layer 5.

[0047] The carrier board 8, reclaimed from the multi-layer panel 2, is then processed further. Here, the carrier board 8 can be turned over so that the original underside 7 of the multi-layer panel 2 is used as the top side 11 of the carrier board 8. This step is optional. Alternatively, the original top side 6 of the multi-layer panel 2 can also be used as the top side 11 of the carrier board 8.

[0048] In the representation according to the Figure 7 The original top surface 6 of the multilayer panel 2 forms the bottom surface 12 of the carrier plate 8, whereas the original bottom surface 7 of the multilayer panel 2 forms the top surface 11 of the carrier plate 8.

[0049] A wear layer 13 is applied to the top surface 11 of the carrier plate 8. For this purpose, an adhesion promoter is applied to the top surface 11. Subsequently, the wear layer 13 is completed. The wear layer 13 can comprise a layer of real wood veneer, cork, fabric, decorative paper, and / or a decorative film. The plate-shaped component 1 according to the invention particularly preferably has a film-based wear layer 13. Decorative films are used here, preferably made of polyethylene terephthalate (PET), polypropylene (PP), or polyolefin (PO). The decorative films are printed on at least one side. Such decorative films are available ready for use.

[0050] The application of the wear layer 13, including an outer, top-side wear layer, can be carried out in a press, in particular a plate press. This is done in single-element production, whereby the carrier plate 8 is provided with an adhesion promoter and the wear layer 13 on its top side. Individual carrier plates 8 can be bonded sequentially, or several carrier plates 8 can be bonded in parallel or simultaneously, each with a wear layer 13. This can be done by wet lamination, dry lamination, or thermal lamination. The bonding can be achieved using heat, heat and pressure, or pressure and extended pressing times. Individual plate-shaped components can be pressed sequentially, in parallel, or stacked on top of each other.

[0051] In particular, the adhesion promoter is an adhesive that is applied in film form or as a hot melt. A water-based adhesive can also be applied to the top surface.

[0052] A pre-finished surface coating is applied to the adhesion promoter layer as a wear layer 13. The wear layer 13 is bonded to the top surface. In particular, the wear layer 13 can be bonded to the substrate 8 in a pressing or rolling process. The wear layer 13 can be stored on a roll, unrolled, and joined to the substrate 8, whereby the wear layer 13 is cut to the required lengths from the roll and fixed to the top surface 11 of the substrate 8. The application of the wear layer 13 can be a classic roll lamination or a wrapping process.

[0053] A counter-layer 14 is applied to the underside of the carrier plate 8. The new counter-layer 14 is applied to the original decorative layer 4 on the top side 6 of the multi-layer panel 2.

[0054] The carrier plates 8, provided with the wear layer 13, are then stacked and cured. In a subsequent process step, the carrier plate 8 undergoes edge profiling. Here, the carrier plates 8 are profiled along at least two opposing parallel side edges 15, 16. This is done by mechanical processing, whereby connecting elements 17, 18 are formed on the side edges 15, 16.

[0055] The invention provides a system for the reuse of multi-layer panels 2 from a second-hand application. The method creates new panel-shaped building elements 1 in a cost-effective manner with a low CO2 footprint. The carrier panels 8, manufactured from a multi-layer panel 2, already possess all the necessary barrier layers. A thin, structured wear layer 13 with a new surface finish is applied to the upper surface. In this way, multi-layer panels 2 from a second-hand application can be reused for many years in both residential and commercial applications. Reference symbol:

[0056] 1 - Component 2 - Multi-layer panel 3 - Panel body 4 - Decorative layer 5 - Backing layer 6 - Top side of 2 7 - Bottom side of 2 8 - Carrier layer 9 - Fastener 10 - Fastener 11 - Top side of 8 12 - Bottom side of 8 13 - Wear layer 14 - Backing layer 15 - Edges 16 - Edges 17 - Fastener 18 - Fastener

Claims

1. A panel-shaped building element (1), in particular a floor panel, which has a carrier plate (8) and a top-side wear layer (13), characterized in that the carrier plate (8) is made of a multi-layer panel (2) from a secondary use.

2. Component according to claim 1, characterized in that the carrier plate (8) consists of a laminate flooring element, a wood material, a polymer plastic material or a mineral mixture.

3. Component according to claim 1 or 2, characterized in that original underside (7) of the multi-layer panel (2) forms the top side (11) of the carrier plate (8).

4. Component according to claim 1 or 2, characterized in that the wear layer (13) is constructed in several layers.

5. Component according to one of claims 1 to 4, characterized in that the wear layer (13) comprises a decorative paper and / or a decorative film.

6. Component according to one of claims 1 to 5, characterized in thatthe wear layer (13) has a decorative film, wherein the decorative film consists of polyethylene terephthalate (PET), polypropylene (PP) or polyolefin (PO) and is printed on at least one side.

7. Component according to claim 6, characterized in that the decorative film has an abrasion-resistant coating and / or a varnish on the top side.

8. Component according to one of claims 1 to 6, characterized in that connecting means (17, 18) are provided on the side edges (15, 16) of the carrier plate (8).

9. Component according to claim 8, characterized in that the connecting means are designed with click and / or snap-in connecting elements.

10. Component according to one of claims 1 to 9, characterized in that a counter-pull (14) is provided on the underside of the carrier plate (8).

11. A method for producing panel-shaped building elements (1), in particular floor elements, comprising the following steps: - providing a multi-layer panel (2) from a secondary use; - processing the multi-layer panel (2) to form a carrier panel (8); - applying a wear layer (13) to an upper side (11) of the carrier panel (8); - profiling the carrier panel (8) along at least two mutually opposite parallel side edges (15, 16) and forming connecting means (17, 18) on the side edges (15, 16).

12. Method according to claim 11, characterized in thatthe processing of the multilayer panel (2) comprises one or more of the following processing steps: - surface processing of the multilayer panel, in particular cleaning, brushing and / or sanding a surface of the multilayer panel (2); - edge trimming of the multilayer panel (2); - application of a layer or coating, in particular an adhesion promoter, to a surface of the multilayer panel (2).

13. Method according to claim 11 or 12, characterized in that the underside (7) of the multi-layer panel (2) is used as the top side (11) of the carrier plate (8).

14. Method according to one of claims 11 to 13, characterized in that the wear layer (13) is formed in several layers.

15. Method according to one of claims 11 to 14, characterized in that a counter-pull (14) is applied to the underside of the carrier plate (8).

16. Method according to one of claims 11 to 15, characterized in thatthe multi-layer panel (2) from a secondary use or the carrier plate (8) made from the multi-layer panel (2) is treated with a disinfectant, in particular treated on all sides, and / or an odorous substance is applied to the multi-layer panel (2) from a secondary use or the carrier plate (8).

17. Method according to one of claims 11 to 16, characterized in that the plate-shaped components (1) are provided with a marking, in particular a marking on the underside, from which the characteristic properties of a plate-shaped component (1) can be derived, in particular that it is a plate-shaped component (1) from a secondary use.

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