Pressing device, apparatus and method for forming floor elements

Abstract

A pressing device for manufacturing a floor element, wherein the floor element comprises an upper decorative layer and a lower supporting layer, wherein the pressing device comprises: a pressing device for pressing the upper decorative layer onto the lower supporting layer; a positioning device for placing the floor element in a pressing position at the pressing element; and a centering device for adjusting the mutual position of the upper decorative layer and the lower supporting layer.

Description

[0001] Cross-reference to related applications

[0002] This application claims priority to U.S. Patent Application No. 16 / 572,944, filed on September 17, 2019, the disclosure of which is incorporated herein by reference in its entirety. Technical Field

[0003] The present invention relates to a pressing device for forming floor elements. In particular, the present invention relates to a pressing device for forming floor elements, the floor elements comprising an upper decorative element (e.g., a tile or a natural stone), and a lower supporting element (e.g., a supporting element comprising a polymer material such as an LVT board or an SPC board). The present invention also relates to an installation and a method for manufacturing floor elements. Background Art

[0004] US7,984,600B2 discloses an apparatus and method for forming a mortarless tile comprising a ceramic tile and a supporting substrate. The floor element is manufactured by placing the ceramic tile into a mold and then injecting a polymeric substance forming the substrate into the mold so that the substrate is formed directly on the ceramic tile. Although this method is fast and effective, it requires expensive molds designed based on the specific product to be manufactured (and, in particular, its size). In addition, the method is only suitable for manufacturing substrates made of injection moldable materials. It should also be noted that the method disclosed in US 7,984,600 is used to manufacture floor elements with a substrate, which floor elements include connecting elements that must be machined after the injection molding step. Therefore, during the machining step, the machining tool may contact the ceramic tile, causing damage to the ceramic tile.

[0005] EP3130464A1 discloses an apparatus and method for forming floor elements comprising stone tiles and a supporting polymer substrate. The method provides for spreading a granular thermoplastic material on a belt, pre-compacting the thermoplastic material to form a reticulated soft layer, placing the stone tiles on the reticulated soft layer, and then hot pressing the stone tiles and the reticulated soft layer to form the floor elements. After the hot pressing step, the product reticulated material must be cut to separate the floor elements. Furthermore, in the case where coupling elements are required, these coupling elements must be manufactured on the floor elements with the stone tiles in a separate machining step, similar to the method of US7,984,600. Furthermore, the method is only suitable for manufacturing substrates with thermoplastic granular material as raw material.

[0006] The present invention first aims to provide an alternative pressing device and method for manufacturing floor tiles. According to its preferred embodiments, the present invention aims to solve one or more problems occurring in the prior art. Summary of the invention

[0007] In a first aspect, the present invention provides a pressing device for manufacturing a floor element, wherein the floor element comprises an upper decorative layer and a lower supporting layer, wherein the pressing device comprises: a pressing device for pressing the upper decorative layer onto the lower supporting layer, a positioning device for placing the floor element in a pressing position at the pressing element, and a centering device for adjusting the relative position of the upper decorative layer and the lower supporting layer.

[0008] In a second aspect, the invention provides a pressing device for manufacturing a floor element, wherein the floor element comprises an upper decorative layer and a lower supporting layer, wherein the device comprises: a pressing device; a carrier for moving the floor element along a forward direction during pressing; and at least one centering element for maintaining the mutual position between the upper ceramic element and the lower supporting element during pressing.

[0009] In a third aspect, the present invention provides a facility for manufacturing floor elements, comprising a pressing device for pressing an upper decorative layer and a lower supporting layer together, the facility also comprising a gluing device configured to provide glue on the surface of the decorative layer and / or the lower supporting layer, the gluing device being arranged upstream of the pressing device.

[0010] These and other objects, features and advantages of the present invention will become more apparent when the following description is read in conjunction with the accompanying description, claims and drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate various aspects of the following description.

[0012] Figure 1 A top plan view of a floor element is shown;

[0013] Figure 2 Shown on a larger scale according to Figure 1 The cross section along line II-II is shown;

[0014] Figure 3 shows a side view of a pressing device according to a first embodiment of the present invention;

[0015] Figures 4a to 4c Shown along Figure 3 A section along line IV-IV of , wherein the pressing device is in a different configuration;

[0016] Figure 5 Shown on a larger scale Figure 3 Detail of V cross section;

[0017] Figure 6 Shown along Figure 3 The section of line VI-VI;

[0018] Figure 7 shows a side view of a pressing device according to a second embodiment of the present invention;

[0019] Figure 8 It is along Figure 7 Side view of line VIII;

[0020] Fig. 9 Shown on a larger scale in a first configuration along Figure 7 Detail of the section along line IX-IX;

[0021] Fig.10 Shows Fig. 9 The cross section of

[0022] Fig.11 Shown on a larger scale in the second configuration along Figure 7 Detail of the section along line IX-IX;

[0023] Fig.12 A schematic diagram of a facility for manufacturing floor elements is shown. DETAILED DESCRIPTION

[0024] Furthermore, according to a first independent aspect, the invention relates to a pressing device for manufacturing a floor element, wherein the floor element comprises an upper decorative layer and a lower supporting layer, wherein the device comprises: a pressing device for pressing the upper decorative layer onto the lower supporting layer; a positioning device for placing at least one of the layers in a pressing position at the pressing element; and a centering device for adjusting the mutual position of the upper decorative layer and the lower supporting layer. Thus, the invention provides a device that allows to assemble the different elements of the floor element precisely without the need for additional machining steps. Furthermore, the invention provides a solution for speeding up the assembly process, since the centering can be done directly at the pressing position without the need for a previous intermediate step.

[0025] Preferably, the floor elements are of the type disclosed in US application 16 / 278,560, which is incorporated herein by reference.

[0026] It should be noted that in a preferred embodiment, the upper decorative layer is a tile. According to different embodiments, the upper decorative layer can be made of different materials, preferably hard and / or brittle materials, such as glass, natural stone, cement board, mineral board and / or artificial stone, metal.

[0027] It should also be noted that the lower support layer can be made of synthetic materials (such as polymer materials, or polymer-based composite materials). For example, the lower support layer can be made of flexible PVC, or preferably made of rigid PVC. The PVC lower support layer can preferably contain one or more fillers (such as particles and / or fibers). Alternatively, the support layer can be made of mineral materials or cement-based materials (such as fiber cement materials). A preferred example of a mineral material is magnesium oxide. A preferred example of a cement-based material is Portland cement. Mineral boards or cement-based substrates can contain fibers, such as cellulose fibers, wood fibers and / or glass fibers.

[0028] The floor element preferably further comprises an intermediate layer between the upper decorative layer and the lower supporting layer. The intermediate layer may be a bonding and / or reinforcing layer, i.e. the intermediate layer may be configured to bond the upper layer and the lower layer together and / or to strengthen the performance of the upper layer and / or the lower layer under mechanical stresses like tension, compression, torque and / or impact stress. Preferably, the intermediate layer may comprise glue and / or resin, even better substantially consist of glue and / or resin. Preferably, the supporting layer comprises a sanded and / or roughened top surface (the surface facing the decorative layer) to improve the adhesion of the glue and / or resin.

[0029] It should also be noted that, according to a preferred embodiment of the present invention, the support layer comprises a coupling element configured to form a mechanical connection with a coupling element of an adjacent coupling element. Preferably, these coupling elements may comprise a convex portion (e.g., a tongue) and a concave portion (e.g., a groove). Preferably, the coupling element is at least partially arranged on the edge of the support layer. These coupling elements may be at least partially covered with a removable lining, such as a polymer film. The lining may prevent glue and / or resin from overflowing on the coupling element during pressing. The final overflow may impair the coupling ability of the final product. The lining may be removed (e.g., peeled off) after manufacturing the floor element. In order to prevent glue from overflowing, in addition to or as an alternative to the lining, the support layer and / or the decorative layer may comprise one or more grooves or channels configured to collect the overflowing portion of the glue. The groove is preferably parallel to the edge of the decorative layer and / or the support layer.

[0030] Preferably, at least one layer between the upper layer and the lower supporting layer includes an edge extending beyond the upper edge and / or the lower edge of the other layer. In some embodiments, the size of the upper layer and the lower supporting layer may be different (specifically in the horizontal plane). For example, the supporting layer includes at least one edge extending beyond the upper edge of the upper ceramic layer. In an alternative example, the upper layer may include at least one edge extending beyond the lower edge of the supporting layer. It is also not excluded that in some embodiments, both the upper layer and the supporting layer include some edges extending beyond the edge of the upper layer or the lower layer, respectively. It is also preferred that a mark or a mark is provided on one of the extending edges to indicate a specific edge of the supporting layer and / or the decorative layer, whereby it is possible to identify which edge should be the edge to be extended, and to place the relevant layer with the correct orientation in the pressing device. The mark or mark may be a cutout and / or a two-dimensional mark (such as text, pattern or barcode), preferably the mark or mark is a mark readable with an optical reader.

[0031] It should be noted that in the context of the present application, the terms "lower" and "upper" with respect to the layers of the floor element may be interpreted with reference to the relative position of the layers during use of the floor element itself. Thus, it is not excluded that the floor element is manufactured upside down, i.e. the decorative layer is in a lower position relative to the supporting layer.

[0032] In a preferred embodiment, the positioning device is adapted to interact with only one layer selected between the lower supporting layer and the upper decorative layer. This provides the possibility to position one of the multiple layers of the floor element and then independently adjust the mutual position of the two layers by the centering element according to the product specifications. In an alternative embodiment, the positioning device is configured to interact with more than one layer, for example with all layers of the floor element.

[0033] The positioning device is suitable for interacting with one or more edges of the layer to be positioned. Specifically, the positioning device includes at least a first pair of contact surfaces, which are suitable for contacting the relative edges of the layer to be positioned in the pressing position, that is, at least one between the support layer or the ceramic layer. Preferably, the positioning device is also provided with a second pair of contact surfaces suitable for contacting the relative edges of the layer to be positioned. It should be noted that, advantageously, the first pair of contact surfaces and the second butted contact surfaces are transverse to each other, preferably orthogonal to each other. Thus, the layer to be positioned is constrained between these contact surfaces, and the position of these contact surfaces relative to the pressing device substantially defines the pressing position. It should also be noted that, according to a preferred embodiment, the positioning device is suitable for contacting the layer to be positioned without contacting glue, for example, being positioned in a distal position relative to the surface to be glued. The positioning device can also include a removable covering or lining, which is removed when the glue contacts and dries on the positioning device.

[0034] In a preferred embodiment, the positioning device comprises at least one movable element adapted to adjust the distance between the contact surfaces of a pair of contact surfaces. Preferably, the movable element is provided with one of the pair of contact surfaces and is configured to move the contact surface closer to / or further away (preferably in a direction substantially orthogonal to these contact surfaces) from the other of the pair of contact surfaces. Preferably, the positioning device comprises at least one movable element for each pair of contact surfaces. The positioning device may also comprise one movable element for each of these surface pairs, so that these surface pairs can be brought closer to and / or further away from each other. Selectively varying the distance between the contact surfaces allows the positioning device to be adapted to the product specifications. In fact, the movable element of the positioning device allows the use of a die-free press capable of manufacturing floor elements of different sizes and / or with different characteristics without the need to change the die. For product changes, it is sufficient to change the movement conditions of the positioning device in order to change the distance between the contact surfaces, thereby increasing the flexibility of the process.

[0035] Preferably, the movable element is movable in a plane that is substantially flat relative to the plane of the floor element. In a preferred embodiment, for a simple construction of the device, the movable element is movable along a straight line. In some embodiments of the invention, the movable elements of each pair of contact surfaces can be moved synchronously. According to an alternative embodiment, each movable element can be moved independently of the other movable elements. For example, the positioning device may include an actuator configured to move the movable elements. In a preferred embodiment, the positioning device may include an actuator for moving a plurality of movable elements, preferably all movable elements, associated with each pair of contact surfaces.

[0036] The centering device is preferably adapted to interact with only one layer selected between the support layer and the ceramic layer. More preferably, the centering device is adapted to interact with a layer of the floor element which does not interact with the positioning device. This provides the possibility to adjust the mutual position of the two layers by the centering element according to the product specifications. In an alternative embodiment, the centering device is configured to interact with more than one layer, for example with all layers of the floor element.

[0037] Preferably, the centering device is suitable for interacting with one or more edges of the layer to be centered. In a preferred embodiment, the centering device comprises at least a first pair of abutment surfaces, which are suitable for contacting the opposite edges of the layer to be centered (i.e., at least one layer between the support layer or the ceramic layer). Preferably, the centering device is also provided with a second pair of abutment surfaces, which are suitable for contacting the opposite edges of the layer to be positioned. It should be noted that, advantageously, the first pair of abutment surfaces and the second pair of abutment surfaces are transverse to each other, preferably orthogonal to each other. It should also be noted that, according to a preferred embodiment, the centering device is suitable for contacting the layer to be centered without contacting the glue, for example being positioned in a distal position relative to the surface to be glued. The centering device may also include a removable covering or lining, which is removed in the case where the glue contacts and dries on the centering device.

[0038] In a preferred embodiment, the centering device comprises at least one movable element, which is suitable for adjusting the distance between the adjacent surfaces of a pair of adjacent surfaces so that the decorative layer can be correctly centered on the supporting layer once the supporting layer is positioned in the pressing position. Preferably, the movable element is provided with one of the pairs of adjacent surfaces and is configured to move the contact surface closer to / or away from (preferably in a direction substantially orthogonal to these adjacent surfaces) the other of the pair of adjacent surfaces. Preferably, the centering device comprises a movable element for each pair of adjacent surfaces. The centering device may also comprise a movable element for each adjacent surface of the pair of adjacent surfaces so that these pairs of adjacent surfaces can be closer to and / or away from each other. Selectively changing the distance between the adjacent surfaces allows the centering device to be adapted to the product specifications. In fact, the movable element of the centering device allows the use of a moldless press, which is able to manufacture floor elements of different sizes and / or with different characteristics without the need to change the mold. In order to carry out a product change, it is sufficient to change the movement conditions of the adjacent device to increase the flexibility of the process. Preferably, the movable element is movable in a substantially flat plane relative to the plane of the floor element.

[0039] In a preferred embodiment, for a simple construction of the device, the movable elements can be moved along a straight line. In some embodiments of the invention, the movable elements of each pair of contact surfaces can be moved synchronously. According to an alternative embodiment, each movable element can be moved independently of the other movable elements. For example, the centering device can include an actuator configured to move these movable elements. In a preferred embodiment, the positioning device can include an actuator for moving a plurality of movable elements, preferably all movable elements, associated with each pair of contact surfaces.

[0040] Preferably, the centering device is arranged above the positioning device. More generally, the centering device is arranged in a plane different from the plane of the positioning device.

[0041] In a preferred embodiment, the movable elements of the centering device can be moved independently relative to the movable elements of the positioning device. This independence provides an increase in the flexibility of the device. According to an alternative embodiment, the centering device can be firmly connected to the positioning device at least during the movement of the positioning device. In this embodiment, the centering device can be mechanically coupled to the positioning device, for example fixed to and / or mounted on the positioning device. For example, in a variant of the embodiment, the mutual position of the centering device relative to the positioning device can be set before the start of operation according to the product specifications, and the centering device can then be moved by the positioning device during production.

[0042] In another embodiment, at least one of the positioning device and the centering device (eg both) are fixed and substantially stationary relative to the pressing position.

[0043] In a preferred embodiment, the device may comprise a support structure provided with a support plate on which the floor element (preferably at least one layer between the upper decorative layer and the lower support layer) rests to be pressed. Thus, the pressing position is defined on the support plate. In a preferred embodiment, the positioning device and / or the centering device is mounted on the support structure. In case the positioning device and / or the centering device comprises a movable element, the movable element is movable on the support plate.

[0044] Preferably, the pressing device comprises one or more pressing elements activated by pneumatic power, oil pressure power, mechanical force and / or hydraulic force. In a preferred embodiment, the pressing element comprises a plurality of pistons suitable for pressing the floor element. The pistons are suitable for pressing the floor element directly or indirectly via an inserted pressing plate. In a preferred embodiment, the pressing elements are independently controllable and / or controllable in groups of pressing elements so that they can be controlled and / or activated according to product specifications. For example, when manufacturing larger floor elements, a larger number of pressing elements can be activated, while when manufacturing smaller floor elements, a smaller number of pressing elements can be activated. Preferably, the pressing device is configured to apply a pressure of at least 350kg / sqm on the floor element. Preferably, the pressing device is configured to apply a pressure of less than 500kg / sqm on the floor element. Preferably, the pressing device is configured to maintain the pressure applied to the floor element for a pressing time of at least 1s.

[0045] The pressing device can be realized according to several possibilities, two of which are disclosed herein as non-exhaustive examples.

[0046] In a first possibility, the pressing device is a fixed pressing device. In the context of the present invention, the term "fixed pressing device" refers to a pressing device in which the floor element is in a fixed pressing position during the pressing operation. In other words, the pressing position is fixed relative to the supporting structure. Preferably, in this first possibility, the pressing element comprises at least one piston, preferably a plurality of pistons.

[0047] In a second possibility, the pressing device is a continuous press. In the context of the present invention, the term "continuous pressing device" refers to a pressing device, wherein the floor element is advanced in a predetermined advancement direction during the pressing operation. In other words, the pressing position is movable relative to the supporting structure. In this second possibility, the pressing device comprises a carrier, preferably a belt, adapted to move the floor element along the advancement direction. Preferably, according to this second possibility, the pressing device comprises at least one pressing belt and / or at least one pressing roller.

[0048] In a preferred form of this second possibility, the positioning device and / or the centering device are fixed in a predetermined position relative to the pressing device and / or the carrier. Preferably, in a preferred form of the second aspect, the positioning device and / or the centering device can be moved along the advancing direction together with the pressing device and / or the carrier. For example, the positioning device can be fixed to the carrier and the centering device can be fixed to the pressing device, preferably to the belt. Specifically, the positioning device can be basically formed by a accommodating cavity arranged on the pressing device and / or the carrier, and the accommodating cavity is defined by a wall (on which the adjacent surface and / or the contact surface are arranged). The cavity can be provided in the form of a depression or embossing formed in the surface of the carrier and / or the pressing belt. Alternatively, the cavity can be defined by a plurality of ribs rising from the surface of the carrier and / or the pressing belt. Preferably, the ribs are made of a polymer material, preferably a compressible material.

[0049] According to another version of this second possibility, the positioning device and / or the centering device comprises a movable element for adjusting the distance between a pair of contact surfaces and / or a pair of abutment surfaces, respectively. Preferably, the movable element is movable at least in a direction transverse to, preferably substantially perpendicular to, the advancement direction of the floor element. Preferably, the contact surfaces and / or the abutment surfaces are substantially parallel to the advancement direction. It should also be noted that, according to this version, the positioning device and / or the centering device can be independent of the movement of the pressing device and of the carrier, that is, the positioning device and / or the centering device does not move along the advancement direction.

[0050] The pressing device may further comprise one or more carriers adapted to transport one or more of the layers of the floor element towards the pressing position and / or to transport the floor element away from the pressing position. For example, the carrier may comprise one or more belts and / or a mechanical arm provided with gripping means. The carrier may be configured to move the layers towards an entrance opening of the supporting structure and / or to transport the floor element away from an exit opening of the supporting structure. Preferably, the entrance opening and the exit opening are placed on different sides of the supporting structure, for example on opposite sides. It should be noted that in this second possibility, the positioning device and the centering device are configured to maintain the position of the floor element in the pressing position and to maintain the mutual position between the upper decorative layer and the lower supporting layer, respectively, during the movement along the advancement direction.

[0051] The fact that the continuous pressing device comprises means for maintaining the mutual position between the upper decorative layer and the lower supporting layer during pressing forms the inventive concept independently of the other features of the pressing device described with respect to the first aspect. Thus, according to a second independent aspect, the invention relates to a pressing device for manufacturing a floor element, wherein the floor element comprises an upper decorative layer and a lower supporting layer, wherein the device comprises: a pressing device; a carrier for moving the floor element in an advancing direction during pressing; and at least one centering element for maintaining the mutual position between the upper ceramic element and the lower supporting element during pressing. The second aspect allows the manufacturing of multilayer floor elements without further processing steps such as cutting or milling and ensures a high productivity by means of a continuous press.

[0052] The pressing device (and, in particular, the positioning means and / or the centering means) comprises one or more of the features described in relation to the first aspect.

[0053] Specifically, in a preferred embodiment of the second aspect, the positioning device and / or the centering device are fixed in a predetermined position relative to the pressing device and / or the carrier. Preferably, in this second embodiment of the second aspect, the positioning device and / or the centering device can be moved along the advancing direction together with the pressing device and / or the carrier. In one embodiment, the positioning device can be fixed to the carrier and the centering device can be fixed to the pressing device, preferably to the belt. In this second embodiment, the positioning device can be basically formed by a accommodating cavity arranged on the pressing device and / or the carrier, and the accommodating cavity is defined by a wall (on which the adjacent surface and / or the contact surface are arranged). The cavity can be provided in the form of a depression or embossing formed in the surface of the carrier and / or the pressing belt. Alternatively, the cavity can be defined by a plurality of ribs rising from the surface of the carrier and / or the pressing belt. Preferably, the ribs are made of a polymer material, preferably a compressible material.

[0054] According to a third independent aspect, the present invention relates to an installation for manufacturing floor elements, the installation comprising a pressing device for pressing together an upper decorative layer and a lower supporting layer, the installation further comprising a gluing device configured to provide glue on the surface of the decorative layer and / or the lower supporting layer, the gluing device being arranged upstream of the pressing device. It should be noted that the fact that the installation comprises a gluing device forms an inventive concept independent of the features of the pressing device. According to a preferred embodiment, the pressing device comprises one or more of the features described with respect to the first and second independent aspects.

[0055] The gluing device is preferably configured to apply glue in a liquid, viscous and / or pasty state. Alternatively, other forms of glue may be applied, such as solid forms (such as powder form or sheet form). According to a preferred embodiment, the gluing device comprises a sprayer for spraying or ejecting glue from a nozzle. According to an alternative embodiment, the gluing device may comprise a roller or a yarn-like applicator or a bell-shaped applicator.

[0056] The glue is preferably a resin, and even more preferably a thermosetting resin. For example, an epoxy, acrylic or polyurethane-based. The glue may be a two-component resin, in which case the gluing device may include a mixing element to mix the two components of the resin, and preferably, the mixing device may be configured to mix the two components before and / or during the application of the glue. The mixing element may be a tube with internal fins. The two components of the glue flow together in the mixing element so that the turbulence caused by the fins allows the mixing of the components. The mixing element is preferably positioned near the nozzle (in the case of a sprayer) of the gluing device so that the hardening reaction of these components will not damage (e.g., clog the nozzle) the gluing device. In the case where the glue is a two-component resin or more generally a multi-component resin, the facility may also include a plurality of gluing devices, wherein each of the gluing devices may be configured to apply one or more of the components.

[0057] In the case where the gluing device comprises a roller, the gluing device may comprise means for avoiding hardening of the resin on the gluing device itself. For example, the means may comprise a removable film covering the roller. Thus, the film may be easily removed and replaced without requiring long and expensive cleaning cycles.

[0058] The gluing device may be configured to apply the glue to form a uniform layer and / or to form a predetermined pattern. More preferably, the gluing device is configured to apply the glue in a manner to prevent the resin from spilling over the edge of the layer of floor elements and / or onto the coupling elements. For example, the gluing device may be configured to provide the glue at a predetermined distance from the edge. For example, in case the gluing device comprises a roller, the roller may comprise a relief having the shape and / or size of the pattern and / or the layer of glue and the relief being adapted to be pressed onto the surface of the layer on which the glue may be provided.

[0059] Preferably, the viscosity of the resin at 20°C is lower than 1000 cP, preferably lower than 750 cP, even more preferably lower than 500 cP.

[0060] The gluing device may comprise a heating element to heat the glue or at least one of its components before providing the glue onto the layers. The gluing device may further comprise a pump and / or a valve assembly to control the flow of the glue.

[0061] The installation may also comprise a handling device for stacking the decorative layer on the supporting layer (or vice versa). The handling device may be, for example, a pantograph robot or a humanoid robot and provided with gripping means. The handling device is advantageously arranged before the pressing device, more preferably between the gluing device and the pressing device.

[0062] In some embodiments of the invention, the installation may further comprise one or more cleaning devices configured to clean the edges of the layers and / or the connecting elements to remove possible glue residues that have overflowed beyond the edges of the layers. The cleaning devices may comprise, for example, a brush configured to scrub the edges of the floor elements and / or the connecting elements. The cleaning devices are placed at least downstream of the gluing device, more preferably downstream of the pressing device, and may be before and after the pressing device.

[0063] Advantageously, the facility may comprise an optical reader configured to read a mark or logo provided on the support layer and / or on the decorative layer. The mark or logo may identify a specific edge of these layers and / or a specific connecting element to check whether the layers are provided to the pressing device in the correct orientation. Identifying the correct orientation of these layers (preferably at least the lower support layer) is useful for correctly adjusting the relative positions between these layers in the pressing device. The optical reader may be replaced by any equivalent detection device suitable for detecting a mark or logo. The detection device may be contactless or contact-type. The optical reader or the detection device may be arranged downstream of the pressing device, preferably downstream of the gluing line.

[0064] Advantageously, the installation comprises a storage area arranged downstream of the pressing device, at which storage area the floor elements pressed in the pressing device can rest during aging and / or curing of the glue.

[0065] In another independent aspect, the present invention relates to a method for manufacturing a floor element, comprising the following steps: providing at least a first layer to a pressing device; providing a second layer to the pressing device; adjusting the position of the first layer in a pressing position at the pressing device; adjusting the position of the second layer relative to the first layer; pressing the first layer and the second layer together.

[0066] The first layer and the second layer may include any of the features described above with respect to the decorative layer and the support layer.

[0067] Preferably, the step of providing the first layer to the pressing device and the step of providing the second layer to the pressing device are performed simultaneously. For example, the method may also include the step of stacking the first layer on top of the second layer. The step of stacking is performed upstream of the pressing device, and the method then includes the step of providing these stacked layers to the pressing device.

[0068] Preferably, during the pressing step, a pressure of at least 350 kg / sqm, more preferably at least 370 kg / sqm, is applied to the layer. According to a preferred aspect of the invention, during the pressing step, the pressure is maintained for a pressing time greater than 1 second, preferably for a pressing time greater than 10 seconds, for example 30 seconds.

[0069] The method may further comprise the step of applying glue between the layers. Preferably, the method comprises the step of providing glue on the layer before providing at least one of the layers to the pressing device. More preferably, the step of providing resin is performed before the step of stacking the layers. The glue is preferably provided on the layer in an amount greater than 150 g / sqm, more preferably in an amount greater than 200 g / sqm, for example 220 g / sqm.

[0070] The step of providing glue may include the step of spraying and / or rolling glue on the layer. The step of providing glue may include the step of mixing components of the glue. The step of providing glue may include the step of heating at least one of the glue or its components.

[0071] The resin may be provided to form a uniform layer or a predetermined pattern.Preferably, the coating or pattern is provided at a predetermined distance from the edge of the layer to prevent glue from overflowing over the edge and / or onto the coupling elements.

[0072] Preferably, pressing is performed to spread the glue on the layers to form a uniform intermediate layer between the first layer and the second layer. More preferably, the pressing step is performed so that the glue forms an intermediate layer that covers at least 80% of the surface of the layers (preferably the smaller layers between the layers). Preferably, pressing is performed so that the intermediate layer covers 80% to 95% of the surface of the layers (preferably the smaller layers between the layers).

[0073] Preferably, the method comprises the step of storing the floor element for a storage time to allow the resin to at least partially cure before packaging, transport and / or use in the floor covering. Preferably, the storage time is a time that allows the resin to be at least 70% cured, preferably 85% cured, more preferably fully cured. For example, the storage time is at least 0.5 h, preferably more than 1 h, such as 2 h.

[0074] The method may further comprise a step of roughening (eg sanding) the surface of the layer suitable for receiving glue. Preferably, the roughening step is performed before the step of providing glue.

[0075] The method may be performed by the plant as described above and in particular by one or more of the means and / or devices described in relation to the plant.

[0076] In order to better illustrate the features of the present invention, several preferred embodiments are described below in the form of examples without any limiting features with reference to the accompanying drawings, in which:

[0077] Figure 1 A top plan view of a floor element is shown;

[0078] Figure 2 Shown on a larger scale according to Figure 1 The cross section along line II-II is shown;

[0079] Figure 3 shows a side view of a pressing device according to a first embodiment of the present invention;

[0080] Figures 4a to 4c Shown along Figure 3 A cross section along line IV-IV of , wherein the pressing device is in a different configuration;

[0081] Figure 5 Shown on a larger scale Figure 3 Detail of V cross section;

[0082] Figure 6 Shown along Figure 3 The section of line VI-VI;

[0083] Figure 7 shows a side view of a pressing device according to a second embodiment of the present invention;

[0084] Figure 8 It is along Figure 7 Side view of line VIII;

[0085] Fig. 9 Shown on a larger scale in a first configuration along Figure 7Detail of the section along line IX-IX;

[0086] Fig.10 Shows Fig. 9 The cross section of

[0087] Fig.11 Shown on a larger scale in the second configuration along Figure 7 Detail of the section along line IX-IX;

[0088] Fig.12 A schematic diagram of a facility for manufacturing floor elements is shown.

[0089] Figure 1 There is shown a floor panel 1 comprising an upper decorative layer 2 and a lower supporting layer 3. The floor panel 1 has a rectangular or oblong shape with a longitudinal length L being greater than a transverse width W thereof.

[0090] The upper decorative layer 2 has an upper surface 4 comprising a decoration 5. The decoration 5 can be provided with a variety of textures, designs and colors. In the example shown, the decoration 5 simulates a wood pattern including wood veins and flakes. Preferably, the decoration 5 is realized by digital printing (such as inkjet printing), although screen printing, rotogravure printing, flexographic printing or offset printing are not excluded.

[0091] Figure 2 Shown on a larger scale along Figure 1 According to the preferred example shown, the decorative layer 2 is essentially composed of ceramic tiles. The ceramic tiles include a body 6 made of a ceramic material, such as red ceramic or porcelain. The ceramic tiles of the decorative layer 2 preferably include one or more covering layers 7 covering the upper surface of the body 6. The covering layer 7 preferably includes at least a glaze that essentially forms the upper surface 4 of the upper decorative layer 2. The decoration 5 is covered by the covering layer 7 or included in the covering layer.

[0092] Figure 2 Also shown is a thickness T1 of the decorative layer 2 , which is comprised between 4 and 15 mm, for example 6 mm, preferably greater than 7 mm, for example 8 mm or 10 mm.

[0093] Although tiles constitute the preferred solution for forming the upper decorative layer 2 , this upper decorative layer may alternatively be formed from natural stone, glass, ceramic glass material, concrete, mineral slabs or artificial stone.

[0094] The lower support layer 3 is preferably made of a polymer material, preferably a thermoplastic material (such as PVC). In a preferred embodiment, the board is made of rigid PVC. In the context of this specification, "rigid" means that the board is bent less than 10 cm per meter under its own weight, and better less than 5 cm per meter. The lower support layer 3 can also include a large amount of filler material (such as chalk), for example, this filler material is greater than 30wt% or greater than 60wt%. It is also not excluded that the lower support layer 3 can include a fiber material (such as cellulose or wood fiber), or also include wood particle material embedded in the polymer material.

[0095] Although polymer materials constitute the preferred solution for forming the lower supporting layer 3, the lower supporting layer may alternatively be formed by a cement substrate, a mineral substrate or a board made of other materials such as metal. Preferably, the cement may be Portland cement and the cement substrate may comprise a fiber cement board, i.e. a cement board containing fibers. Preferably, the mineral may be magnesium oxide or other metal oxides and the mineral substrate may comprise a fiber mineral board, i.e. a mineral board containing fibers.

[0096] Furthermore, the thickness T2 of the lower supporting layer 3 is preferably comprised between 2 mm and 7 mm, preferably less than 6 mm, for example about 4 mm.

[0097] Figure 2 It is also shown that the lower supporting layer 3 comprises an edge 8 provided with coupling elements 9, 10, which are configured to achieve a mechanical coupling with coupling elements 9, 10 of adjacent floor elements 1. In the example shown, the coupling elements 9, 10 comprise a male and a female portion provided on opposite edges 8. The male and female portions are shaped in the form of a tongue 9 and a groove 10, respectively, wherein the tongue 9 protrudes outwardly beyond its respective edge 8 in a horizontal direction X, and the groove 10 protrudes inwardly relative to the respective edge 8 in said horizontal direction X.

[0098] The lower supporting layer 3 extends beyond the edge 11 of the upper decorative layer 2. In the example, the lower supporting layer 3 comprises an upper edge 12 at said edge 8, which extends beyond the edge 11 of the upper decorative layer 2 by a distance D1. In the preferred and shown example, said distance D1 is equal on all sides of the floor element 1. In practice, the lower supporting layer 3 is larger than the upper decorative layer 2.

[0099] Although in the preferred example, the lower support layer 3 extends beyond all edges 11 of the upper decorative layer 2, it is not excluded that in alternative embodiments, the lower support layer 3 may extend only beyond some of the edges 11 of the upper decorative layer 2, and the upper decorative layer 2 extends beyond some of the edges 8 of the lower support layer 3. In addition, in another alternative embodiment, the upper decorative layer 2 may extend beyond all edges 8 of the lower support layer 3. In another alternative embodiment, the edge 11 of the upper decorative layer 2 may substantially coincide with the edge 8 of the lower support layer 3.

[0100] Figure 2 It is also shown that the floor element 1 comprises an intermediate layer 13 arranged between the upper decorative layer 2 and the lower supporting layer 3. The intermediate layer 13 comprises a resin material, such as a thermosetting resin or a thermoplastic resin. Examples of thermosetting resins are epoxy resins, polyurethanes, cyanoacrylates, unsaturated polyesters, vinyl esters or acrylic resins. Examples of thermoplastic resins are hot melts, polyester thermoplastics, vinyl, etc. Preferably, the resin is a rigid resin. In particular, according to a preferred embodiment of the present invention, the intermediate layer 13 comprises an epoxy resin. It is also preferred that the epoxy resin is a two-component resin, i.e. a thermosetting resin obtained by curing a mixture of two components, i.e. a resin and a hardener, at low temperatures, e.g. at room temperature. Furthermore, in a preferred embodiment, the resin has a viscosity of less than 1000 cP in an uncured state at 20°C, and / or a porosity that penetrates the upper decorative layer 2 (i.e. the body 6 of the tile).

[0101] It should also be noted that the floor element may include one or more features of the floor element described in US application 16 / 278,560, which is incorporated herein by reference.

[0102] Figure 3 Shown for manufacturing Figure 1 and Figure 2 Side view of a pressing device 20 for a floor element 1 shown in . The device 20 comprises a supporting structure 21 provided with a supporting plate 22 on which the floor element 1 (preferably at least one layer between an upper decorative layer 2 and a lower supporting layer 3) rests to be pressed.

[0103] The pressing device 20 further comprises a pressing means 23 for pressing together the layers 2, 3 of the floor element 1. The pressing means 23 are supported by the supporting structure 21 above said supporting plate 22. The pressing means 23 are able to exert pressure along a vertical direction Y on the layers 2, 3 of the floor element.

[0104] The device further comprises positioning means 24 and centering means 25 adapted to adjust the position of the lower supporting layer 3 above the supporting plate 22 and to adjust the mutual position of the upper decorative layer 2 and the lower supporting layer 3 of the floor element 1, respectively.

[0105] The pressing device 20 further comprises a carrier 26 adapted to transport the layers 2, 3 to the support plate 22. Preferably, the same transport means is also adapted to remove the floor element 1 from the support plate 22. In the example shown, the carrier 26 comprises a transport belt.

[0106] Figures 4a to 4c Shown along Figure 3 A cross section of line IV-IV, wherein the pressing device is in a different configuration. Figures 4a to 4c As can be seen in FIG. 2 , the carrier 26 spans the support structure 21 so that the layers 2 , 3 can approach the support plate through an inlet opening 27 in the support structure 21 and the floor elements 1 can leave the support plate through an outlet opening 28 on the opposite side of the support structure 21 .

[0107] According to a preferred embodiment shown in Figure 4, the positioning means 24 comprises two pairs 29 of contact surfaces 30, wherein each pair 29 of contact surfaces 30 is adapted to contact opposite edges 8 of the lower supporting layer 3. The first and second pairs 29 of contact surfaces 30 are orthogonal to each other, such that the first pair 29 is adapted to interact with the short edges 8 of the lower supporting layer 3 and the second pair 29 of contact surfaces 30 is adapted to interact with the long edges 8 of the lower supporting layer 3.

[0108] In a preferred embodiment, the positioning device 24 comprises a plurality of movable elements 31 adapted to adjust the distance between the contact surfaces 30. Each movable element 31 is provided with one contact surface 30 and is configured to move said contact surface 30 closer to / or further away from the other of the pair 29 of contact surfaces 30 (preferably in horizontal directions X, Z substantially orthogonal to these contact surfaces 30).

[0109] Preferably, the movable elements 31 are movable substantially along a straight line in a horizontal plane. In the example shown, these movable elements are movable along sliding guides 32. In particular, each movable element 31 is movable along a corresponding sliding guide 32. In the example shown, the movable elements 31 provided with the contact surfaces 30 of the first pair 29 are movable along sliding guides 32, which are oriented along a horizontal direction X substantially perpendicular to the short edge 8 of the lower support element 3. Similarly, the movable elements 31 provided with the contact surfaces 30 of the second pair 29 are movable along sliding guides 32, which are oriented along a horizontal direction Z substantially perpendicular to the long edge 8 of the lower support element 3.

[0110] In the embodiment shown in Fig. 4, the centering means 25 are adapted to interact only with the upper decorative layer 2. This provides the possibility to adjust the mutual position of the two layers 2, 3 of the floor element 1 according to the product specifications.

[0111] The centering means 25 comprise two pairs 33 of abutment surfaces 34 suitable for contacting opposite edges 11 of the upper decorative layer 2. It should be noted that, advantageously, the first and second pairs 33 of abutment surfaces 34 are transverse to each other, preferably orthogonal to each other, so that the first pair 33 of abutment surfaces 34 are suitable for interacting with the short edges 11 of the upper decorative layer 2 and the second pair 33 of abutment surfaces 34 are suitable for interacting with the long edges 11 of the upper decorative layer 2.

[0112] In a preferred embodiment, the centering device 25 comprises a plurality of movable elements 35 adapted to adjust the distance between the abutment surfaces 34 of each pair 33 of abutment surfaces 34. Preferably, each movable element 35 is provided with one abutment surface 34 of the pair 33 and is configured to move the abutment surface 34 closer to / or further away from (preferably, in directions X, Z substantially orthogonal to the abutment surface 34) the other of the pair 33 of abutment surfaces 34.

[0113] The movable element 35 of the centering device 25 can be moved substantially along a straight line in a horizontal plane. In the example shown, the movable element 35 of the centering device 25 can be moved along a sliding guide 36. In particular, each movable element 35 of the centering device 25 can be moved along a corresponding sliding guide 36. In the example shown, the movable element 35 provided with the first pair 33 of abutment surfaces 3a can be moved along a sliding guide 36, which is oriented along a horizontal direction X substantially perpendicular to the short edge 11 of the upper decorative layer 2. Similarly, the movable element 35 provided with the second pair 33 of abutment surfaces 34 can be moved along a sliding guide 36, which is oriented along a horizontal direction Z substantially perpendicular to the long edge 11 of the upper decorative layer 2.

[0114] As from Figure 4a , Figure 4b and Figure 4c As can be seen in the figure, the centering device 25 is arranged above the positioning device 24. In a preferred embodiment, the centering device 25 is independent of the positioning device 24. Specifically, the centering device 25 can be moved independently relative to the movement of the positioning device 24.

[0115] Figure 4aThe pressing device 20 is shown in a first configuration, wherein the layers 2, 3 for forming the floor element 1 are placed on the support plate 22 and wherein the positioning means 24 and the centering means 25 do not interact with the layers 2, 3. Thus, in this configuration, the layers 2, 3 of the floor element 1 are not yet in a pressing position and the mutual position between the layers has not yet been adjusted. In this first configuration, the movable element 31 of the positioning means 24 is in a retracted position, wherein the mutual distance between the contact surfaces 30 of each pair 29 of contact surfaces 30 is at its maximum value and / or more generally is greater than the corresponding dimensions W, L of the supporting layer 2. Similarly, the movable element 35 of the centering means 25 is in a retracted position, wherein the mutual distance between the abutment surfaces 34 of each pair 33 of abutment surfaces 34 is at its maximum value and / or more generally is greater than the corresponding dimensions of the upper decorative layer 3.

[0116] Figure 4b The pressing device 20 is shown in a second configuration, wherein the layers 2, 3 for forming the floor element 1 are placed on a supporting plate 22, wherein the positioning means 24 interact with the lower supporting layer 2 to place it in the pressing position, and wherein the centering means 25 do not interact with the upper decorative layer 3. In this second configuration, the movable element 31 of the positioning means 24 is in an operating position, wherein the mutual distance between the contact surfaces 30 of each pair 29 of contact surfaces 30 is at its minimum value and / or more generally substantially equal to a corresponding dimension L, W of the supporting layer 2. In this operating position, each contact surface 30 of the positioning means 24 is in contact with a respective edge 8 of the lower supporting layer 2. Furthermore, in this second configuration, the movable element 35 of the centering means 25 is in a retracted position, wherein the mutual distance between the abutment surfaces 34 of each pair 33 of abutment surfaces 34 is at its maximum value and / or more generally greater than a corresponding dimension of the upper decorative layer 3. For example, the centering means 25 is in a Figure 4a The same construction as shown in .

[0117] Figure 4cThe pressing device 20 is shown in a third configuration, wherein the layers 2, 3 for forming the floor element 1 are placed on the supporting plate 22, and wherein the positioning means 24 and the centering means 25 interact with the layers 2, 3. In this third configuration, the movable element 31 of the positioning means 24 is in an operating position, wherein the mutual distance between the contact surfaces 30 of each pair 29 of contact surfaces 30 is at its minimum value and / or more generally substantially equal to the corresponding dimensions L, W of the supporting layer 2. Furthermore, in this operating position, each contact surface 26 of the positioning means 24 is in contact with a respective edge 8 of the lower supporting layer 2 to hold it in the pressing position. Similarly, the movable element 35 of the centering means 25 is in an operating position, wherein the mutual distance between the abutment surfaces 34 of each pair 33 of abutment surfaces 34 is at its minimum value and / or more generally substantially equal to the corresponding dimensions of the upper decorative layer 2. In this operating position, each abutment surface 34 of the centering means 25 is in contact with a respective edge 11 of the upper decorative layer 2.

[0118] Figure 5 Shown on a larger scale Figure 3 Detail V of the cross section. Figure 5 As can be seen in the figure, the positioning device 24 comprises an actuator 31 configured to move the movable element 30 between the retracted position and the operating position. In the embodiment shown, the centering device comprises one actuator for each movable element. In an alternative embodiment, the actuator can be configured to move multiple movable elements of the positioning device, preferably all movable elements. In the example shown, the actuator comprises a linear actuator, such as a piston, having a rod connected to the lower part of the movable element and a cylinder connected to the support structure.

[0119] also, Figure 5 The centering device 25 is shown to include an actuator 37 configured to move the movable element 35 between the retracted position and the operating position. In the embodiment shown, the centering device 25 includes one actuator 37 for each movable element 35. Thus, in the embodiment shown, each movable element 35 can be moved independently of the other movable elements. In an alternative embodiment, the actuator 37 can be configured to move multiple movable elements 35 of the centering device, preferably all of the movable elements. In the example shown, the actuator 37 is a linear actuator, such as a piston, which has a rod connected to the lower part of the movable element and a cylinder connected to the support structure.

[0120] Figure 5It is also shown that the positioning device 24 includes an actuator 38, which is configured to move the movable element 31 between the retracted position and the operating position. In the embodiment shown, the positioning device 24 includes an actuator 38 for each movable element 31. Therefore, in the embodiment shown, each movable element 31 can be moved independently of the other movable elements. In an alternative embodiment, the actuator 38 can be configured to move multiple movable elements 34 of the positioning device, preferably all movable elements. In the example shown, the actuator 38 is a linear actuator, such as a piston, which has a rod connected to the lower part of the movable element and a cylinder connected to the support structure 21.

[0121] In an alternative embodiment, one actuator is able to move the movable element 31 of the positioning device 24 and the movable element 35 of the centering device 25 together.

[0122] Figure 6 Shown along Figure 3 The cross section of the line VI-VI of FIG. 2 shows the pressing device 23. In the embodiment shown, the pressing device 23 is a fixed pressing device 23. Figure 6 As can be seen, the pressing device 23 comprises a plurality of pressing elements 39. In the example shown, the pressing elements 39 are pistons activated by pneumatic, oil, mechanical and / or hydraulic forces. The pressing elements are suitable for directly pressing the floor element 1. In the embodiment shown, each pressing element 39 comprises: a cylinder 40 fixed to the support structure; and a retractable rod 41 having an end portion suitable for pressing on the floor element (e.g., on the upper surface 4 of the decorative layer 2).

[0123] Preferably, the pressing elements 39 are individually controllable and / or controllable in groups of pressing elements 39, so that they can be controlled and / or activated depending on the product specification. For example, for the production of larger floor elements 1, a greater number of pressing elements 39 can be activated, while for the production of smaller floor elements 1, a smaller number of pressing elements 39 can be activated.

[0124] Preferably, the pressing device 23 is configured to exert a pressure of at least 350 kg / sqm on the floor element 1. Preferably, the pressing device is configured to exert a pressure of less than 500 kg / sqm on the floor element. Preferably, the pressing device is configured to maintain the pressure exerted on the floor element for a pressing time of at least 1 s.

[0125] Figures 7 to 10A pressing device 20 according to a second embodiment of the invention is shown, wherein the pressing means 23 is a continuous pressing device, wherein during the pressing operation the floor element 1 is advanced in a predetermined advancement direction A. In other words, the pressing position is movable relative to the support structure 21. In this second possibility, the pressing device 20 comprises a carrier 26, preferably a belt, adapted to move the floor element 1 along the advancement direction A. In this embodiment, the carrier 26 preferably replaces the support plate 22 of the first embodiment, although this is not necessary. Preferably, as from Figure 7 It can be seen that the pressing device 23 comprises a pressing belt.

[0126] exist Figure 7 and Figure 8 In the embodiment of the present invention, the centering device 25 is fixed at a predetermined position relative to the belt of the pressing device 23. In addition, the positioning device 24 is fixed at a predetermined position relative to the carrier 26. Therefore, the positioning device 24 and the centering device 25 can move along the advancing direction A.

[0127] As from Fig. 9 and Fig.10 It can be seen that the positioning device 24 is essentially formed by a housing cavity 40 provided on the carrier 26, and the centering device 25 is essentially formed by a housing cavity 41 provided on the pressing device 23. The housing cavity 40 of the positioning device 24 is defined by a wall on which the contact surface 30 is arranged. Similarly, the housing cavity 41 of the centering device 25 is defined by a wall on which the abutment surface 34 is arranged. In the example shown, the walls defining the cavities 40, 41 of the positioning device 24 and the centering device are formed by ribs 42 rising from the surface of the carrier 26 and the pressing belt 23. Preferably, the ribs 42 are made of a polymer material, preferably a compressible material.

[0128] Fig.11 A variant of the second embodiment is shown, in which the centering means 25 and the positioning means 24 are formed in one piece by the same accommodation cavity 43. In this variant, the walls defining the accommodation cavity 43 are shaped in such a way as to define a lower narrow portion 44 of the cavity 43, which is suitable for accommodating the upper decorative layer 2, for example, and an upper larger portion 45 of the cavity 43, which is suitable for accommodating the lower supporting layer 3, for example. In this variant, the floor element 1 is pressed, for example, upside down. In the example shown, the walls of the cavity 43 are formed by ribs 42 rising from the surface of the carrier 26. Preferably, the ribs 42 are made of a polymer material, preferably a compressible material.

[0129] Fig.12A schematic diagram of a facility 50 or production line for manufacturing floor elements 1 is shown. The facility 50 comprises one or more carriers 55 which transport the layers 2, 3 of the floor elements 1 through the facility 50 itself along the advancing direction A. The carriers 55 may coincide with the carriers 26 of the pressing device 20 or may be separate from the carriers 26 of the pressing device 20.

[0130] The device 50 may include an optical reader 57 configured to read a mark or logo provided on the support layer 3. The mark or logo may identify a specific edge 8 of the lower support layer and / or a specific coupling element 9, 10 to check whether the lower support layer has the correct orientation. Identifying the correct orientation of the support layer 3 is useful for correctly adjusting the relative position between the lower support layer 3 and the upper decorative layer. It should be noted that the optical reader 57 may be replaced by any equivalent detection device suitable for detecting a mark or logo.

[0131] The installation 50 shown in the example comprises a gluing device 51 configured to provide glue on the top surface of the lower supporting layer 3 on the carrier 55, thereby performing a step S1 of providing said glue in the method for manufacturing the floor element 1. The gluing device 51 comprises a sprayer having one or more nozzles for spraying the glue onto said top surface. It is not excluded that in alternative embodiments the gluing device 51 comprises a roller or other application or gluing means. The gluing device 51 is configured to provide the glue in a pattern, but in alternative embodiments the gluing device 51 is configured to provide the glue as a uniform coating on the top surface of the lower supporting layer 3.

[0132] The installation 50 further comprises a handling device 53 arranged downstream of the gluing device 51, which is configured to stack the lower supporting layer 3 and the upper decorative layer 2 one on top of the other in the stacking step S2 of the method. For example, the handling device 53 comprises a pantograph-like robot 54 provided with gripping means to grip the decorative layer 2 and place it above the supporting layer 3, thereby stacking the two layers. At this stage, the lower supporting layer 3 and the upper decorative layer 2 are not yet bonded to each other and the mutual position can be adjusted in the pressing device 20. This handling device is completely optional and the two layers 2, 3 can be stacked directly in the pressing device 20.

[0133] A pressing device 20 is arranged downstream of the handling device 53. In a preferred embodiment, the pressing device is the one described above. Figures 3 to 6In the example, the stacked layers 2, 3 for forming the floor element 1 are arranged in a pressing position at the pressing device 20. The positioning device 24 adjusts the position of the lower supporting layer 3 on the pressing position at the pressing device 20. The centering device 25 then adjusts the position of the decorative layer 2 on the lower supporting layer 3. The positioning device 24 and the centering device 25 maintain the position of the layers during the pressing step S3.

[0134] The installation 50 may include a plurality of compression devices 20 .

[0135] The installation 50 further comprises a cleaning device 56 (eg a brush) configured to clean glue residues that eventually overflow beyond the edges of the layers 2, 3 on the coupling element. Preferably, the cleaning device 56 is arranged downstream of the pressing device 20 in the cleaning step S4.

[0136] The facility 50 also includes a storage area 52 arranged downstream of the pressing device 20, in which the floor elements 1 pressed in the pressing device 20 can be placed during aging and / or curing of the glue and before the floor elements are subjected to further processing steps (for example, quality control checks and packaging steps in storage step S5).

[0137] The invention is by no means limited to the embodiments described above, but such a device and / or arrangement may be implemented according to different variants without departing from the scope of the invention.

[0138] In addition, it can be clearly seen from the contents of the specification that the present invention relates to one or more of the following items, numbered 1 to 48:

[0139] 1. A pressing device for manufacturing a floor element, wherein the floor element comprises an upper decorative layer and a lower supporting layer, wherein the device comprises: a pressing device for pressing the upper decorative layer onto the lower supporting layer; a positioning device for placing the floor element in a pressing position at the pressing element; and a centering device for adjusting the relative position of the upper decorative layer and the lower supporting layer.

[0140] 2. A pressing device according to item 1, wherein at least one of the upper layer and the lower supporting layer includes an edge extending beyond an upper edge and / or a lower edge of the other layer.

[0141] 3. Pressing device according to any of the preceding items, wherein the positioning means is adapted to interact with one or more layers selected between the lower supporting layer and the upper decorative layer.

[0142] 5. Pressing device according to any of the preceding items, wherein the positioning means is adapted to interact with one or more edges of the layer to be positioned.

[0143] 6. Pressing device according to any of the preceding items, wherein the positioning means comprises at least a first pair of contact surfaces adapted to contact opposite edges of a layer to be positioned in the pressing position.

[0144] 7. A pressing device according to item 6, wherein the positioning device is provided with a second pair of contact surfaces, which are suitable for contacting opposite edges of the layer to be positioned, advantageously, the first pair of contact surfaces and the second pair of contact surfaces are transverse to each other, preferably orthogonal to each other.

[0145] 8. The pressing device according to item 6 or 7, wherein the positioning means comprises at least one movable element adapted to adjust the distance between the contact surfaces of the pair of contact surfaces.

[0146] 9. A pressing device according to item 8, wherein the movable element is provided with one contact surface of a pair of contact surfaces, and the movable element is configured to preferably move the contact surface closer to / or away from the other contact surface of the pair of contact surfaces along a direction substantially orthogonal to these contact surfaces.

[0147] 10. A compression device according to any of items 8 to 9, wherein the positioning means comprises at least one movable element for each pair of contact surfaces.

[0148] 11. A compression device according to any one of items 8 to 10, wherein the positioning means comprises a movable element for each surface of a pair of surfaces, so that the surfaces of the pair of surfaces can be moved closer to and / or further away from each other.

[0149] 12. A compression device according to any one of items 10 or 11, wherein the movable elements of each pair of contact surfaces can be moved synchronously.

[0150] 13. A compression device according to any one of items 10 or 11, wherein each movable element can be moved independently of the other movable elements.

[0151] 14. A compression device according to any one of items 8 or 13, wherein the positioning device may include an actuator configured to move a movable element, preferably one actuator for moving a plurality of, advantageously all, movable elements associated with each pair of contact surfaces.

[0152] 15. A pressing device according to any of the preceding items, wherein the centering device is preferably adapted to interact with only one layer selected between the support layer and the ceramic layer, preferably the centering device is adapted to interact with a layer of the floor element that does not interact with the positioning device.

[0153] 16. Pressing device according to any of the preceding items, wherein the centering means are adapted to interact with one or more edges of the layer to be centered.

[0154] 17. Pressing device according to any of the preceding items, wherein the centering means comprises at least a first pair of abutment surfaces adapted to contact opposite edges of the layer to be centered.

[0155] 18. Pressing device according to item 17, wherein the centering means are provided with a second pair of abutment surfaces adapted to contact opposite edges of the layer to be positioned.

[0156] 19. A pressing device according to item 17 or 18, wherein the centering means comprises at least one movable element adapted to adjust the distance between abutment surfaces in a pair of abutment surfaces.

[0157] 20. A pressing device according to item 19, wherein the movable element is provided with one of a pair of adjacent surfaces, and the movable element is configured to preferably move the contact surface closer to / or away from the other adjacent surface of the pair of adjacent surfaces along a direction substantially orthogonal to these adjacent surfaces, and advantageously, the centering device includes one of the movable elements for each pair of adjacent surfaces.

[0158] 21. A pressing device according to item 20, wherein the centering device comprises a movable element for each abutment surface of a pair of abutment surfaces, so that the pair of abutment surfaces can approach and / or move away from each other.

[0159] 22. The compression device according to item 21, wherein the movable elements of each pair of contact surfaces can be moved synchronously.

[0160] 23. A compression device according to item 22, wherein the positioning means may comprise an actuator for moving a plurality, preferably all, of the movable elements associated with each pair of contact surfaces.

[0161] 24. The compression device according to item 21, wherein each movable element is movable independently of the other movable elements.

[0162] 25. A pressing device according to any one of items 21 to 24, wherein the movable element of the centering device is independently movable relative to the movable element of the positioning device.

[0163] 26. Compression device according to any of items 21 to 24, wherein the centering device is firmly coupled to the positioning device at least during the movement of the positioning device.

[0164] 27. Pressing device according to any of the preceding items, comprising a support structure provided with a support plate on which a floor element, preferably at least one layer between an upper decorative layer and a lower support layer, rests to be pressed.

[0165] 28. The pressing device according to any one of the preceding items, wherein the pressing means comprises one or more pressing elements actuated by pneumatic power, oil hydraulic power, mechanical force and / or hydraulic force.

[0166] 29. The compression device according to any of the preceding items, wherein the compression means comprises a plurality of compression elements and wherein the compression elements are controllable individually and / or in groups of compression elements.

[0167] 30. A pressing device according to any of the preceding items, wherein the pressing device is configured to exert a pressure of at least 350 kg / sqm on the floor element and / or the pressing device is configured to exert a pressure of less than 500 kg / sqm on the floor element.

[0168] 31. The compression device according to any of the preceding items, wherein the compression means is a fixed compression means.

[0169] 32. A pressing device according to any of items 1 to 30, wherein the pressing device is a continuous pressing device, for example, wherein the pressing device comprises a carrier, preferably a belt, adapted to move the floor element in an advancing direction during pressing.

[0170] 33. The pressing device according to item 32, wherein the pressing device comprises at least one pressing belt and / or at least one pressing roller.

[0171] 34. The pressing device according to item 32 or 33, wherein the positioning device and / or the centering device is fixed in a predetermined position relative to the pressing device and / or the carrier.

[0172] 35. Pressing device according to any of items 32 to 34, wherein the positioning device and / or the centering device can be moved along the advancement direction together with the pressing device and / or the carrier.

[0173] 36. Pressing device according to item 35, wherein the positioning means are fixed to the carrier and the centering means are fixed to the pressing means, preferably to the belt.

[0174] 37. A pressing device according to any one of items 35 or 36, wherein the positioning device and / or the centering device can be basically formed by an accommodating cavity arranged on the pressing device and / or on the carrier, and the accommodating cavity is defined by a wall, and the adjacent surface and / or the contact surface is arranged on the wall.

[0175] 38. A pressing device according to item 37, wherein the cavity is provided in the form of a depression or an impression formed in the surface of the carrier and / or the pressing belt.

[0176] 39. Compression device according to item 37, wherein the cavity is defined by ribs rising from the surface of the carrier and / or the surface of the compression belt, preferably the ribs are made of polymer material, preferably a compressible material.

[0177] 40. A pressing device according to any of items 32 or 33, wherein the movable element is movable at least in a direction transversely, preferably substantially perpendicularly, to the advancement direction of the floor element.

[0178] 41. A pressing device according to item 40, wherein the positioning device and / or the centering device is independent of the movement of the pressing device and the carrier, that is, the positioning device and / or the centering device does not move along the advancement direction.

[0179] 42. Pressing device according to any of the preceding items, comprising one or more carriers adapted to transport one or more layers of floor elements towards a pressing position and / or to transport floor elements away from a pressing position.

[0180] 43. A pressing device for manufacturing floor elements, wherein the floor elements include an upper decorative layer and a lower supporting layer, wherein the device includes: a pressing device; a carrier for moving the floor element along a forward direction during pressing; and at least one centering element for maintaining the relative position between the upper ceramic element and the lower supporting element during pressing.

[0181] 44. A compression device according to item 43 and according to any one of items 32 to 42.

[0182] 45. A facility for manufacturing floor elements, comprising a pressing device for pressing an upper decorative layer and a lower supporting layer together, the facility also comprising a gluing device configured to provide glue on the surface of the decorative layer and / or the lower supporting layer, the gluing device being arranged upstream of the pressing device.

[0183] 46. ​​The facility according to item 45, wherein the pressing device is a pressing device according to any one of items 1 to 44.

[0184] 47. Installation according to item 45 or 46, wherein the gluing device comprises a sprayer for spraying or jetting the glue from a nozzle, or comprises a roller or gauze-like applicator or a bell-shaped applicator.

[0185] 48. Installation according to any of items 45 or 47, wherein the installation comprises a storage area arranged downstream of the pressing device, at which storage area the floor elements pressed in the pressing device can rest during aging and / or curing of the glue.

Claims

1. A pressing device (20) for producing a floor element (1), wherein: The floor element comprises an upper decorative layer (2) and a lower supporting layer (3), wherein the device comprises: a pressing device (23) for pressing the upper decorative layer (2) onto the lower supporting layer (3); a positioning device (24) for placing at least one between the lower supporting layer (3) and the upper decorative layer (2) in a pressing position at the pressing device; and a centering device (25) for adjusting the mutual position of the upper decorative layer (2) and the lower supporting layer (3), wherein the centering device (25) is mounted on the positioning device (24), the centering device (25) being arranged on a plane different from the plane of the positioning device (24), wherein the centering device (25) is suitable for interacting with a layer of the floor element that does not interact with the positioning device (24), wherein the positioning device (24) comprises at least a first pair of contact surfaces (30) suitable for contacting a layer to be positioned in the pressing position. The present invention relates to a method for positioning a decorative layer to be positioned so as to position the relative edges of the layer to be positioned, wherein the positioning device (24) is provided with a second pair of contact surfaces (30) adapted to contact the relative edges of the layer to be positioned, the first pair of contact surfaces and the second pair of contact surfaces (30) being transverse to each other, wherein the positioning device (24) comprises at least one movable element adapted to adjust the distance between the contact surfaces in the pair of contact surfaces (30), wherein the centering device (25) is adapted to interact with only one layer selected between the lower supporting layer (3) and the upper decorative layer, wherein the centering device (25) comprises at least a first pair of abutting surfaces adapted to contact the relative edges of the layer to be positioned, wherein the centering device (25) comprises at least one movable element adapted to adjust the distance between the abutting surfaces in the pair of abutting surfaces, wherein the centering device (25) comprises one movable element for each abutting surface in the pair of abutting surfaces.

2. The pressing device (20) according to claim 1, wherein: The positioning device (24) comprises a movable element for each contact surface of a pair of contact surfaces.

3. The pressing device (20) according to claim 2, wherein: The movable elements of each pair of contact surfaces (30) are capable of moving synchronously.

4. The pressing device (20) according to claim 1, wherein: The movable elements of each pair of contact surfaces (30) are capable of moving synchronously.

5. The pressing device (20) according to claim 1, wherein: The movable element of the centering device (25) is independently movable relative to the movable element of the positioning device (24).

6. The pressing device (20) according to claim 1, wherein: The pressing device (23) comprises a plurality of pressing elements (39), wherein the pressing elements (39) are controllable individually and / or in groups of pressing elements (39).

7. The pressing device (20) according to claim 1, wherein: The first pair of contact surfaces and the second pair of contact surfaces (30) are orthogonal to each other.

8. A plant (50) for manufacturing floor elements (1), the plant (50) comprising a pressing device (20) according to any of the preceding claims, the plant further comprising a gluing device (51), the gluing device being configured to provide glue on the surface of the upper decorative layer (2) and / or the lower supporting layer (3), the gluing device (51) being arranged upstream of the pressing device (20).

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