Method for manufacturing a wall or floor with a decoration

Abstract

The invention relates to a method for manufacturing a wall or floor having a decoration, comprising the steps of: a) providing a first molten polymer mass and a second molten polymer mass; b) extruding the molten polymer masses, wherein each polymer mass is extruded in particular by a separate extruder, wherein the layered stacked molten polymer masses are extruded; c) discharging the layered stacked molten polymer masses through a die; d) shaping the layered stacked molten polymer masses into a panel-shaped carrier, the panel-shaped carrier having at least one carrier layer comprising the first polymer mass and a sealable layer comprising the second polymer mass and being in contact with the carrier layer. The invention also relates to a panel-shaped carrier and a decorative panel manufactured thus, and to a device for carrying out the method.

Description

Technical Field

[0001] This invention relates to a method for manufacturing decorative walls or floors, comprising the following steps:

[0002] a) Provide a first molten polymer block and a second molten polymer block;

[0003] b) Extruding molten polymer blocks, wherein each polymer block is extruded by a separate extruder, and the molten polymer blocks are stacked in layers;

[0004] c) Discharge layered, stacked molten polymer blocks through nozzles;

[0005] d) The molten polymer blocks stacked in a shaped layer form a plate-like carrier, the plate-like carrier having at least one carrier layer including a first polymer block and a sealable layer including a second polymer block and in contact with the carrier layer.

[0006] The present invention also relates to an apparatus for manufacturing decorative walls or floors, and walls or floors manufactured according to the above method, a plate-like carrier for decorative walls or floors manufactured according to the above method, and decorative panels manufactured according to the above method. Background Technology

[0007] Decorative panels are known in themselves and are used, for example, in interior decoration as flooring or wall panels. The term "wall panel" is also understood to refer to panels suitable for ceiling cladding. A panel typically comprises a carrier or core made of a solid material such as wood, which has a decorative layer and a top layer on at least one side, and optionally other layers, such as a wear-resistant layer between the decorative layer and the top layer. The decorative layer is typically made of resin-impregnated printed paper. The overlay and remaining layers are also typically made of resin.

[0008] Methods for manufacturing panels typically involve multiple steps. For example, a "cake" of granular particles can be applied to the lower conveyor belt of a press via a spreader. During manufacturing, this cake is typically fed into a hot press with steel and / or PTFE belts, where the granular particles are heated and melted. Simultaneously, the material is pressed and shaped into a carrier. Subsequently, controlled cooling causes the carrier material to solidify or crystallize, where a significant amount of residual waste heat remains unused because the available temperature difference resulting from controlled cooling is too small for any other application. Heat transfer during this belt press operation occurs through contact with the press from above and below. Furthermore, heat must pass through the glass fiber reinforced PTFE belt, which is detrimental to cooling. Only then does heat transfer occur through conduction into the granular filler or carrier material. These physical processes are very slow because the granular cake initially still contains air from the granular filler, which, from a product physics perspective, can only be slowly expelled from the carrier. To achieve satisfactory belt speeds during production, high temperature gradients must be employed for cooling, resulting in considerable waste heat loss.

[0009] Methods for manufacturing decorative walls or floors typically include additional costly process steps, such as applying decorative, overlay, and / or abrasion-resistant layers. Applying these layers often requires laborious heating of components and frequently necessitates multiple process steps to interconnect the desired layers.

[0010] Therefore, the object of the present invention is to provide an improved method for manufacturing decorative walls or floors. Summary of the Invention

[0011] This task is solved by the method according to claim 1, by the apparatus according to claim 13, by the plate-like carrier according to claim 14, and / or by the decorative panel according to claim 15.

[0012] Therefore, the present invention proposes a method for manufacturing decorative walls or floors, comprising the following steps:

[0013] a) Provide a first molten polymer block and a second molten polymer block;

[0014] b) Extrusion of molten polymer blocks, wherein each polymer block is extruded by a separate extruder, and the molten polymer blocks are stacked in layers;

[0015] c) Discharge layered, stacked molten polymer blocks through nozzles;

[0016] d) The molten polymer blocks stacked in a shaped layer form a plate-like carrier, the plate-like carrier having at least one carrier layer including a first polymer block and a sealable layer including a second polymer block and in contact with the carrier layer.

[0017] Surprisingly, the methods described above have been found to improve the manufacturing of walls or floors. By combining the above method steps, high-quality panels with improved decorative properties can be obtained in a very short processing time. In particular, due to the shaping steps according to the invention, the panel has a particularly flat carrier surface, and high-quality decoration can be applied to this carrier surface particularly effectively. Without being limited by theory, the decoration applied according to the invention exhibits particularly high-quality optical properties due to the particularly smooth and defect-free surface of the carrier material. The above methods also enable high flow rates at high roll speeds and reduce the proportion of non-uniform panels.

[0018] Furthermore, a greater proportion of processing energy can be recovered through the shaping-grading sub-steps according to the invention, which generally contributes to lower carbon dioxide (CO2) emissions in the process used, and thus also contributes to lower CO2 emissions in the produced panels.

[0019] The above method also advantageously enables the plate-shaped carrier to possess both good shape stability and, in particular, ease of reprocessing. Specifically, the constructed sealable layer allows for the simple and precise application of other coatings to the plate-shaped carrier. By constructing the sealable layer together with the carrier layer as a plate-shaped carrier, the sealable layer achieves particularly good adhesion to the carrier layer, and furthermore, the sealable layer also benefits from the shaping process.

[0020] The method according to the invention is used to manufacture decorative walls or floors. In the context of this invention, the term "decorative wall or floor" or "decorative panel" specifically refers to a wall, ceiling, or floor that includes decorations that imitate decorative templates and are applied to a carrier board. Decorative panels are used in various ways in the fields of interior design and building cladding, for example, in booth construction. One of the most common uses of decorative panels is as floor coverings. Here, decorative panels often include decorations designed to replicate natural materials.

[0021] Examples of such replicated natural materials or decorative templates include wood species such as maple, oak, birch, cherry, ash, walnut, chestnut, and wenge, as well as exotic woods such as wenge, mahogany, bamboo, and African rosewood. Additionally, natural materials such as stone or ceramic surfaces are often imitated.

[0022] Therefore, the term "decorative template" in the sense of this invention specifically refers to the original natural material or at least one surface of such material being imitated or replicated by the decoration.

[0023] Method step a) includes providing a first molten polymer block and a second molten polymer block. The molten polymer block exhibits at least partially the properties of a flowable viscous liquid and can be obtained, for example, by a heat treatment step of a polymer that is typically in particulate form. Here, the molten polymer block may consist of only one homogeneous polymer block or of several polymer blocks (feed blocks) that are mixed with each other or stacked on top of each other in a defined form. “Particles” or “particulate material” can be understood to mean a solid or aggregate of solids comprising a plurality of solid particles such as fine particles or spheres or composed thereof. By way of example, but not exhaustive, particulate or powdered materials, or suitable recyclable materials existing as abrasive materials, may be mentioned here.

[0024] Preferably, the first polymer block comprises a first solid material, wherein the first solid material preferably comprises a solid material selected from the group consisting of layered silicate powder, chalk powder, and mixtures thereof, and wherein the first solid material particularly preferably comprises talc. This allows the carrier layer to have particularly good mechanical properties while simultaneously possessing good compatibility with the sealable layer.

[0025] In this paper, layered silicate powder is understood to refer to layered silicate powder in a manner known per se. Layered silicate is a known term for silicate minerals whose silicate anions are typically arranged in layers. For example, layered silicates are understood to be minerals from the mica, chlorite, kaolinite, and serpentine groups.

[0026] Therefore, the first solid material is advantageously composed at least largely of a layered silicate mineral material, which can be used in powder form or may exist in granular molten polymer blocks. The first solid material can essentially consist of a powdered solid.

[0027] The advantages offered by layered silicates are that they can be used to produce carriers with good mechanical properties, and at the same time, due to their layered structure, they can be easily processed into corresponding powders.

[0028] In one embodiment of the invention, the layered silicate powder may contain talc. Talc itself is a known magnesium silicate hydrate, which may have a chemical formula such as Mg3[Si4O] 10 [(OH)2]. In another preferred embodiment, the layered silicate powder comprises at least 80 wt% talc, particularly preferably at least 95 wt%.

[0029] Specifically, the advantage of talc is that it allows for the production of carriers in a particularly gentle manner, as it can be embedded into the matrix material without any problems, thus not causing abrasion to the pressing units used.

[0030] In this document, chalk powder is understood to refer to chalk powder in a manner known per se. In the sense of this invention, chalk is understood to be limestone. Specifically, chalk may be essentially composed of calcite.

[0031] A particular advantage of chalk is that, in addition to its advantageous mechanical properties, it can impart a light to white base color to a carrier, thus allowing for a particularly simple color configuration of plate-like carriers.

[0032] Preferably, the first polymer block contains a first solid material in the range of greater than or equal to 50 wt% to less than or equal to 70 wt% of its total mass, preferably in the range of greater than or equal to 55 wt% to less than or equal to 65 wt%, for example, 60 wt%. Surprisingly, this has proven to achieve particularly good mechanical properties.

[0033] Preferably, the first polymer block comprises a first vinyl polymer, wherein the first vinyl polymer is preferably a recycled vinyl polymer, particularly preferably polypropylene, and even more particularly preferably recycled polypropylene. This results in a carrier layer with good elastic properties and easy recyclability.

[0034] Preferably, the first polymer block contains a first solid material in the range of greater than or equal to 50 wt% to less than or equal to 70 wt% of its total mass, preferably greater than or equal to 20 wt% to less than or equal to 40 wt%, and particularly preferably greater than or equal to 20 wt% to less than or equal to 30 wt%.

[0035] The method wherein the first polymer block comprises a first solid material and a first vinyl polymer in a mass ratio ranging from greater than or equal to 2:1 to less than or equal to 4:1, preferably less than or equal to 3:1.

[0036] The aforementioned first polymer block provides a particular advantage in manufacturing panels with excellent moisture resistance. Specifically, by using such a polymer block to construct the carrier layer, the expansion of the resulting panels upon exposure to moisture can be significantly reduced or even completely prevented. Furthermore, heat-related expansion can be prevented or at least significantly reduced. This greatly simplifies the installation or connection of panels made from the first polymer block, and / or significantly reduces problems that occur after the installation or connection of the panels.

[0037] At the same time, the advantage provided by the first polymer block is that the panels made from it have very good stability, resulting in an extremely low risk of damage to the panels during transportation and use. This can be achieved specifically through the first solid material.

[0038] Because the first molten polymer block comprises a first vinyl polymer (e.g., recycled polypropylene), the sheet made from the polymer block can be very elastic or resilient and / or flexible, despite its high stability. This allows for a comfortable impression when walking on it, and further reduces noise when walking on it compared to conventional materials, thus enabling improved footsteps.

[0039] In particular, vinyl polymers have the advantage that products made from them are very easy to recycle. This leads to further reductions in production costs.

[0040] Preferably, the first polymer block comprises at least one polymeric additive selected from the group consisting of an olefin-based thermoplastic elastomer, a first ethylene homopolymer, a first vinyl copolymer, a first tackifier, and a second vinyl copolymer. The first polymer block preferably has at least two polymeric additives, more preferably at least three, more preferably at least four, and particularly preferably at least five. This further improves the properties of the carrier layer.

[0041] Preferably, the first polymer block contains polymeric additives, the total amount of which is greater than or equal to 0 wt% to less than or equal to 25 wt% of the total mass of the first polymer block, preferably greater than or equal to 10 wt% to less than or equal to 20 wt%, and particularly preferably greater than or equal to 15 wt% to less than or equal to 17 wt%.

[0042] Preferably, the first polymer block contains an olefin-based thermoplastic elastomer as a polymer additive, the total amount of which is greater than or equal to 1 wt% to less than or equal to 10 wt% of the total mass of the first polymer block, preferably greater than or equal to 3 wt% to less than or equal to 8 wt%, and particularly preferably greater than or equal to 5 wt% to less than or equal to 7 wt%.

[0043] Preferably, the first polymer block comprises a first ethylene homopolymer as a polymerization additive, wherein the first ethylene homopolymer particularly comprises a polypropylene homopolymer, wherein the first polymer block comprises an ethylene homopolymer comprising a mass of greater than or equal to 1 wt% to less than or equal to 10 wt%, preferably greater than or equal to 3 wt% to less than or equal to 7 wt%, and particularly preferably greater than or equal to 4 wt% to less than or equal to 6 wt%.

[0044] Preferably, the first polymer block comprises a first vinyl copolymer as a polymer additive, wherein the first vinyl copolymer preferably comprises a polypropylene-based vinyl copolymer, particularly preferably a propylene-ethylene random copolymer, wherein the first polymer block comprises the first vinyl copolymer, which accounts for more than or equal to 1 wt% to less than or equal to 5 wt% of the total mass of the first polymer block, particularly preferably more than or equal to 2 wt% to less than or equal to 4 wt%.

[0045] Preferably, the first polymer block contains a first adhesive as a polymer additive, wherein the first adhesive preferably contains a polypropylene adhesive, particularly preferably maleic anhydride-grafted polypropylene, wherein the first polymer block contains the first adhesive in an amount greater than or equal to 1 wt% to less than or equal to 5 wt% of the total mass of the first polymer block, particularly preferably greater than or equal to 2 wt% to less than or equal to 4 wt%.

[0046] Preferably, the first polymer block contains a second vinyl copolymer as a polymer additive, wherein the second vinyl copolymer preferably includes a polypropylene-based vinyl copolymer, particularly preferably linear low-density polyethylene (LLDPE), wherein the first polymer block contains the second vinyl copolymer, which accounts for more than or equal to 0.5 wt% to less than or equal to 3 wt% of the total mass of the first polymer block, particularly preferably more than or equal to 1 wt% to less than or equal to 2 wt%.

[0047] Preferably, the first polymer block comprises a first solid material comprising 50 wt% to 70 wt% of the total mass of the first polymer block; a first vinyl polymer comprising 50 wt% to 10 wt% of the total mass of the first polymer block; an olefin-based thermoplastic elastomer comprising 1 wt% to 10 wt% of the total mass of the first polymer block; a first ethylene homopolymer comprising 1 wt% to 10 wt% of the total mass of the first polymer block; a first vinyl copolymer comprising 1 wt% to 5 wt% of the total mass of the first polymer block; a first tackifier comprising 1 wt% to 5 wt% of the total mass of the first polymer block; and a second vinyl copolymer comprising 0.5 wt% to 3 wt% of the total mass of the first polymer block.

[0048] It can be demonstrated that this composition is particularly suitable for the above method because the resulting plate-shaped carrier has particularly good mechanical properties and can be carried out at particularly high linear speeds.

[0049] Preferably, the second polymer block includes a third polymer, wherein the third polymer is a vinyl copolymer, wherein the third vinyl copolymer preferably comprises a vinyl copolymer derived from the group consisting of polypropylene vinyl copolymers, vinyl terpolymers and mixtures thereof, and particularly preferably comprises a vinyl copolymer derived from the group consisting of propylene-ethylene random copolymers, polypropylene-ethylene-butene copolymers, ethylene-propylene monomer rubbers and mixtures thereof.

[0050] This allows for the very simple application of additional layers to the plate-like carrier. In particular, it enables the plate-like carrier surface to possess exceptionally good sealing properties. For example, it allows the plate-like carrier surface to have a melting point higher than the required sealing temperature. Furthermore, this achieves a good bond between the sealable layer and the carrier layer, and the plate-like carrier as a whole possesses good mechanical properties.

[0051] Preferably, the third vinyl copolymer comprises a mixture including a propylene-ethylene random copolymer and a polypropylene-ethylene-butene copolymer.

[0052] Preferably, the third vinyl copolymer has a melting point measured according to ISO 11357-3, which is in the range of 110°C to 160°C, preferably in the range of 120°C to 150°C, and particularly preferably in the range of 130°C to 140°C.

[0053] Preferably, the third vinyl copolymer has a Vicat softening temperature (A50) as measured according to ISO 306, said Vicat softening temperature being in the range of greater than or equal to 100°C to less than or equal to 120°C, preferably in the range of greater than or equal to 105°C to less than or equal to 115°C.

[0054] Preferably, the third vinyl copolymer has a melt flow rate measured according to ISO 1133-1 (230°C / 2, 16 kg), said melt flow rate being in the range of greater than or equal to 5 g / 10 min to less than or equal to 7 g / 10 min, particularly preferably in the range of 5.5 g / 10 min to less than or equal to 6 g / 10 min.

[0055] Preferably, the third vinyl copolymer has a sealing start temperature in the range of 75°C to 125°C, preferably in the range of 80°C to 115°C, and particularly preferably in the range of 85°C to 100°C.

[0056] In the context of this invention, the sealing start temperature is understood as the minimum temperature at which the third vinyl copolymer can be sealed with the carrier.

[0057] Preferably, the sealing start-up temperature of the third vinyl copolymer is at least 10°C lower than the melting point of the vinyl copolymer, preferably at least 20°C, and particularly preferably at least 25°C.

[0058] The above parameters can ensure that the sealable layer can seal well with the film without melting of the sealable layer and / or deformation of the plate-like carrier.

[0059] Preferably, the second polymer is a thermoplastic vinyl polymer.

[0060] Preferably, the propylene-ethylene random copolymer has an ethylene content in the range of 1 wt% to 10 wt%, preferably 2 wt% to 6 wt%, for example, 4 wt%.

[0061] Preferably, the propylene-ethylene random copolymer has a Vicat softening temperature (A50) as measured according to ISO 306, said Vicat softening temperature being in the range of greater than or equal to 90°C and less than or equal to 120°C, preferably in the range of greater than or equal to 100°C and less than or equal to 110°C.

[0062] Preferably, the polypropylene-ethylene-butene copolymer has a melting point measured according to ISO 11357-3, said melting point being in the range of greater than or equal to 110°C and less than or equal to 150°C, preferably in the range of greater than or equal to 120°C and less than or equal to 130°C.

[0063] Preferably, the polypropylene-ethylene-butene copolymer has a Vicat softening temperature (A50) measured according to ISO 306, said Vicat softening temperature being in the range of greater than or equal to 80°C and less than or equal to 110°C, preferably in the range of greater than or equal to 90°C and less than or equal to 100°C.

[0064] Preferably, the melt flow rates of the first polymer and the second polymer, as measured according to ISO 1133-1 (230°C / 2, 16 kg), are different from each other, and the difference is less than or equal to 3 g / 10 min, preferably less than or equal to 2 g / 10 min, and particularly preferably less than or equal to 1 g / 10 min.

[0065] Preferably, the second polymer block contains a third vinyl copolymer in the range of greater than or equal to 50 wt% to less than or equal to 100 wt% with respect to its total mass, preferably greater than or equal to 55 wt% to less than or equal to 80 wt%, more preferably greater than or equal to 55 wt% to less than or equal to 70 wt%, and particularly preferably greater than or equal to 60 wt% to less than or equal to 65 wt%.

[0066] Preferably, the second polymer block comprises a vinyl-alkyl acrylate copolymer, more preferably a vinyl butyl acrylate copolymer, and particularly preferably vinyl butyl acrylate.

[0067] It may be preferably specified that the second polymer block contains a vinyl-alkyl acrylate copolymer in the range of greater than or equal to 0 wt% to less than or equal to 50 wt% with respect to its total mass, preferably greater than or equal to 10 wt% to less than or equal to 40 wt%, and particularly preferably greater than or equal to 15 wt% to less than or equal to 30 wt%.

[0068] Preferably, the second polymer block contains a color masterbatch, preferably a vinyl polymer-based color masterbatch, and particularly preferably an LDPE-based color masterbatch, wherein the color masterbatch preferably contains a white pigment, preferably titanium dioxide.

[0069] This allows for the advantageous realization of a sealable layer that can also serve as a decorative substrate. Therefore, it is particularly effective for decorative applications on sheet-like substrates.

[0070] It may be preferably specified that the second polymer block contains color masterbatch in the range of greater than or equal to 0 wt% to less than or equal to 10 wt% with respect to its total mass, preferably in the range of greater than or equal to 2.5 wt% to less than or equal to 7.5 wt%, for example 5 wt%.

[0071] Preferably, the second polymer block comprises a second solid material, wherein the second solid material is preferably selected from the group consisting of calcium carbonate and kaolin.

[0072] Preferably, the second polymer block contains a second solid material in the range of greater than or equal to 0 wt% to less than or equal to 50 wt% with respect to its total mass, preferably greater than or equal to 5 wt% to less than or equal to 45 wt%, more preferably greater than or equal to 15 wt% to less than or equal to 40 wt%, and particularly preferably greater than or equal to 25 wt% to less than or equal to 35 wt%.

[0073] Preferably, the second polymer block includes a third vinyl copolymer in the range of 50 wt% to 100 wt% of its total mass, a vinyl-alkyl acrylate copolymer in the range of 0 wt% to 50 wt% of its total mass, a color masterbatch in the range of 0 wt% to 10 wt% of its total mass, and a solid material in the range of 0 wt% to 50 wt% of its total mass.

[0074] It can be demonstrated that this component is particularly suitable for the above method because the resulting plate-like carrier can be fitted with decorations particularly well.

[0075] Preferably, a third molten polymer block is provided in step a), and the plate-like carrier formed in step b) further includes at least one anti-tension layer comprising the third polymer block and in contact with the carrier layer.

[0076] Therefore, it is advantageous to achieve very little warping in the obtained plate-shaped carrier. Furthermore, by manufacturing the anti-tension layer and the other layers of the plate-shaped carrier together, additional method steps for installing the anti-tension layer can be eliminated. This also allows for a particularly good bond between the anti-tension layer and the carrier layer, resulting in exceptional shape stability of the plate-shaped carrier. In addition, the anti-tension layer provides exceptionally good adhesion to the plate-shaped carrier.

[0077] Preferably, the third polymer block comprises a third solid material, wherein the third solid material preferably comprises layered silicate powder, and wherein the third solid material particularly preferably comprises talc. The third solid material of the third polymer block can preferably be defined precisely as the first solid material of the first polymer block. In a preferred embodiment, the third solid material and the first solid material can be specified to be the same.

[0078] Preferably, the third polymer block contains a third solid material in the range of greater than or equal to 10 wt% to less than or equal to 70 wt% with respect to its total mass, preferably greater than or equal to 20 wt% to less than or equal to 60 wt%, and particularly preferably greater than or equal to 30 wt% to less than or equal to 50 wt%.

[0079] It may be preferably specified that the third polymer block comprises a second vinyl polymer, wherein the second vinyl polymer preferably comprises a recycled vinyl polymer, particularly preferably comprises polypropylene, and even more particularly preferably comprises recycled polypropylene.

[0080] This allows for the advantageous establishment of a particularly good reaction force in the anti-tension layer. Without relying on any theory, it is assumed that this can be achieved by the higher shrinkage tendency of the third polymer block compared to the first polymer block.

[0081] Preferably, the first polymer block contains a first solid material in the range of greater than or equal to 30 wt% to less than or equal to 70 wt% of its total mass, preferably greater than or equal to 20 wt% to less than or equal to 80 wt%, and particularly preferably greater than or equal to 20 wt% to less than or equal to 70 wt%.

[0082] Preferably, the third polymer block contains at least one second adhesive aid, wherein the second adhesive aid is preferably selected from polypropylene adhesive aids, vinyl copolymers and mixtures thereof, and particularly preferably from polypropylene grafted with maleic anhydride, ethyl butyl acrylate and mixtures thereof.

[0083] This allows for a particularly good bond between the anti-tension layer and the carrier layer, resulting in exceptionally good mechanical properties for the plate-like carrier. It also enables the plate-like carrier to be bonded very well. In particular, such a plate-like carrier achieves particularly good adhesion to common adhesives such as silane-modified polymer adhesives (SMP) or polyurethane-based adhesives (PU).

[0084] Preferably, the first polymer block contains a first solid material in the range of greater than or equal to 0 wt% to less than or equal to 5 wt% of its total mass, preferably greater than or equal to 1 wt% to less than or equal to 3 wt%, for example 2 wt%.

[0085] Preferably, the first polymer block contains a first solid material in the range of greater than or equal to 10 wt% to less than or equal to 70 wt% of its total mass, preferably greater than or equal to 20 wt% to less than or equal to 90 wt%, and particularly preferably greater than or equal to 20 wt% to less than or equal to 5 wt%.

[0086] To produce molten polymer blocks, one or more so-called dry blends, i.e., dry plastic powder containing fillers, can be melted. These materials can be provided in step a), for example by a screw extruder, in which the polymer material or dry blend is melted, homogenized, and provided, if necessary, by means of pressure, temperature, and shear force, and then provided to step b).

[0087] In step b), molten polymer blocks are extruded, with each block specifically extruded using a separate extruder. The molten polymer blocks can be extruded, for example, in a feed block or a multi-channel nozzle. The molten polymer blocks are layered and stacked. In step c), the layered and stacked molten polymer blocks are discharged through a nozzle. Furthermore, the molten and plasticized polymer blocks are extruded through a nozzle by pressure, where a portion of the final product geometry has been pre-determined appropriately by selecting the nozzle geometry. For panels, slotted nozzles or wide-slot nozzles have proven particularly suitable, with a slot width to slot height ratio greater than about 4:1 (width:height), preferably greater than 10:1, and more preferably greater than 20:1. Especially for panels according to the invention, this relatively wide and narrow nozzle geometry has allowed for pre-forming most of the carrier structure, making it possible to maintain minimal subsequent effort required for shaping the extruded polymer blocks. In particular, wide-slot nozzles with means for adjusting the nozzle roll gap may be advantageous. For example, these devices can be used to make the edge regions of the extruded flat strands extremely flat, so that in a further process step, connections between different panels can be formed in these edge regions that are flatter than the average panel thickness, without requiring extensive shaping work.

[0088] Preferably, the extruded molten polymer block is specified such that the carrier layer has a thickness of 60% or more to 95% or less than the thickness of a plate-like carrier, particularly less than or equal to 90%. This makes the plate-like carrier particularly robust.

[0089] Preferably, the molten polymer block is extruded in such a manner that the sealable layer has a thickness greater than or equal to 5% and less than or equal to 15% of the thickness of the plate-like carrier. This makes the plate-like carrier particularly suitable for decorative applications.

[0090] Preferably, the extruded molten polymer block is designed such that the anti-tension layer has a thickness greater than or equal to 5% and less than or equal to 15% of the thickness of the plate-like carrier. This results in very little deformation of the plate-like carrier.

[0091] In step d), the molten polymer blocks that are shaped and layered are stacked to form a plate-like carrier, the plate-like carrier having at least one carrier layer including a first polymer block and a sealable layer including a second polymer block and in contact with the carrier layer.

[0092] Preferably, shaping is performed by an assembly of multiple rotatable rollers, wherein each roller is positioned above or behind each other, and each individual roller forms at least one shaping gap with the adjacent roller, through which layered, stacked blocks of molten polymer are guided, wherein the height of the shaping gap can be variably adjusted during manufacturing by the horizontal and / or vertical movement of the individual rollers.

[0093] In particular, according to the present invention, incorporating the roller shaping step into the production process can reduce the percentage of air inclusions at the panel surface, thanks to improved removal of air present in the carrier and improved removal of air from the roller gap. In addition to direct process advantages, the flexible process using individually controllable rollers can also reduce shop setup and break-in time, resulting in higher processing efficiency.

[0094] The forming and shaping of the panel is not performed using a flatbed press, but rather using rollers. A block of molten polymer passes through the gaps between the rollers formed by the roller assembly, and due to the mechanical stress within the gaps, the polymer block is compressed and reaches the desired thickness. In addition to the mechanical force applied by the rollers, the polymer block can also be cooled simultaneously. This can be accomplished by the rollers or by other cooling devices, such as blowing air. It is surprising that efficient shaping can be achieved through the roller assembly and the gaps, given that the viscoelastic properties of the molten polymer block are suitable for presses with large surface areas. The smaller active shaping surface in the gaps, compared to a press, should mean that insufficient shaping is achieved at these small surfaces due to the rheological properties of the polymer block, such as thixotropic properties. However, surprisingly, this is not the case, thus enabling efficient and time-saving production through an assembly of multiple rollers. Here, "multiple rollers" refers to more than four rollers, such as five rollers, where the multiple rollers form at least three or four separate gaps. The gaps are preferably arranged one after another, separated by the rollers. In particular, according to the invention, it is also provided that the shaping of the carrier is performed solely by passing the molten carrier material through the roll gap. Here, according to the invention, the method can also completely abandon the use of sheet-like pressing equipment, such as a belt press. It is also possible to make the shaping of the carrier determined solely by rollers arranged directly and continuously one after another at a single location in the equipment. In this case, the division of the roller assembly, for example, first two roll gaps, then, for example, a cooling section, and then one or two roll gaps, is not according to the invention. According to the invention, it can be further provided that shaping is performed directly after the carrier material is extruded, omitting further important shaping or leveling steps.

[0095] During manufacturing, the height of the shaping roll gap can be variably adjusted by moving the individual rollers horizontally or vertically. This means that changes in the position of each roller also alter the roll gap size of one or more gaps formed by adjacent rollers. Thus, the roll gap size, and therefore the carrier height, can be affected by the distance between the rollers. Furthermore, the relative height of the rollers to each other can alter the pull-out angle or incident angle of the molten polymer material from or on the rollers, which can result in different mechanical forces, potentially different cooling performance and area, and possible air entrainment between the rollers and the polymer. If the rollers can change their X and / or Y positions as the polymer material passes through them, the rollers are variably adjustable during manufacturing. During manufacturing, the individual roll gaps can be controlled either isobarically or isochorically. The former operating mode results in mechanical forces on the polymer carrier material in the roll gap, while the latter operating mode is based on a constant thickness of the roll gap between the two rollers. Therefore, in the former operating mode, the position of the rollers is dynamically adjusted, while in the latter operating mode, the position of the rollers relative to each other remains relatively constant.

[0096] It is particularly advantageous to set different shaping gaps between several or all rollers. This can counteract fluctuations in carrier thickness that occur during production, as well as the potentially non-uniform cooling performance of the individual rollers. Each roller can simply operate together or support the transport of the film, which is why it is also possible to provide rollers that can be driven individually or together. Depending on the roller positioning, the carrier material can pass through the roller in a quasi-wavy line, thus contacting one side of the continuous roller once and the other side once. To ensure that the effect of the contact area between the roller and the carrier surface is substantially the same on both sides of the carrier, it can be provided that the diameters of the main roller and the downstream roller are selected such that the contact surface between the carrier and the roller is substantially the same on both sides of the carrier. When passing through the respective rollers, only one side of the extrudate is cooled at a time, which can potentially create stress in the sheet. To counteract this non-uniform cooling forming, for example, the rear side can be actively cooled by introducing cold air (e.g., an air knife) to achieve a more uniform cooling effect on the carrier.

[0097] Since cooling behavior can vary with the width of the extrudate, and to counteract the necking effect, heat can also be utilized in the edge regions on opposite sides. For example, an IR emitter can be used for this purpose. Other measures for uniformly cooling the molded polymer block can be a vacuum chamber that ensures the polymer melt is applied to the rollers without air, or so-called edge pin connections, where the edge regions are electrostatically fixed to the rollers.

[0098] By means of the method according to the invention, the carrier not only has a particularly smooth surface with low roughness, but also a surface with particularly low air inclusions. These two factors can contribute to a particularly reproducible and high-quality decorative carrier final product. Unbound by theory, air in the carrier can escape better compared to a flatbed press due to the relatively small volume in the gap between the roll pairs. This can result in a carrier and carrier surface with particularly low air inclusions. By introducing a second white polymer melt on the upper side of the molten and extruded polymer, a smooth, non-porous printing underlayer can be applied, unlike prior art solutions which do not require a coating of non-polymer-based thermosetting materials. Here, it is advantageous that it consists of a thermoplastic polymer matrix that is almost identical to the carrier sheet. The latter is highly advantageous for efficient recycling.

[0099] In one embodiment, the decoration of the replica decorative template is applied to at least a portion of the sealable layer. The application of the decorative template can be performed after the shaping carrier has passed through the roller assembly or before it has passed through the last shaping roller clamp. By the method according to the invention, the carrier not only has a particularly smooth surface with low roughness but also a surface with particularly low air inclusions. These two factors can contribute to a particularly reproducible and high-quality decorative carrier final product. Unrestricted by theory, air in the carrier can escape better compared to a flat press due to the relatively small volume in the gap between the roller pairs. This can result in a carrier and carrier surface with particularly low air inclusions. A smooth, non-porous printed underlayer can be applied by introducing a second white polymer melt on the upper side of the molten and extruded polymer, unlike prior art solutions which do not require a coating of non-polymer-based thermosetting materials. Here, it is advantageous that it consists of a thermoplastic polymer matrix that is almost identical to the carrier sheet. The latter is highly advantageous for efficient recycling.

[0100] Furthermore, the decoration, which replicates the decorative template, is applied to at least a portion of the carrier. Here, the decoration can be applied, for example, by so-called direct printing. In the context of this invention, the term "direct printing" should be understood as applying the decoration directly to the carrier of the panel or to a non-printable fibrous material layer applied to the carrier or to a decorative sub-layer. Different printing techniques can be used, such as flexographic printing, offset printing, or screen printing. In particular, inkjet or laser printing processes can be used as digital printing techniques.

[0101] For example, in order to imitate or replicate a three-dimensional decorative template in a particularly fine and highly accurate manner, the decoration can be applied in the same manner as the original after passing through the roller assembly. In particular, three-dimensional decorative data can be provided by three-dimensional scanning of the decorative template using electromagnetic radiation, for example, by a 3D scanner. Here, based on the provided three-dimensional decorative data, multiple decorative layers with at least partially different surface applications can be applied sequentially.

[0102] Furthermore, the decorative layer can be formed from, in particular, radiation-curable paints and / or inks. For example, UV-curable paints or inks can be used. In this embodiment, particularly fine and matching replication of the decorative template can be achieved. On the one hand, synchronized holes can be achieved with high precision in this way without providing further measures. Here, synchronized holes can be, in particular, holes or another type of structure that are spatially precisely set at positions optically represented by tactile structures corresponding to optical decorative features. In this embodiment, this is essentially automatic because the structural design is precisely generated by the pigments or inks. In addition, decorative templates such as those made of wood-based materials typically exhibit color impression variations not only along their width or length but also along their depth. In this embodiment, this color impression or color gradient can also be replicated with particularly fine detail, which also makes the overall appearance of the panel more consistent. Therefore, particularly when the paints or inks used are radiation-curable, particularly rapid curing can be achieved, thereby allowing multiple layers to be quickly superimposed on each other, which also makes the entire process feasible in a shorter time and therefore has particularly high efficiency.

[0103] In the context of this invention, the term radiation-curable coating should be understood as a composition comprising binders and / or fillers and colored pigments, which can be induced at least partially polymerized by electromagnetic radiation of a suitable wavelength, such as UV radiation or electron radiation.

[0104] Therefore, in the sense of this invention, the term radiation-curable ink should be understood to refer to a substantially filler-free composition containing colored pigments that can be at least partially polymerized by electromagnetic radiation of a suitable wavelength, such as UV radiation or electronic radiation.

[0105] Here, the thickness of the decorative layer can be between ≥5μm and ≤10μm.

[0106] It can also be specified that, in terms of color and / or structure, in addition to the positive image, a corresponding negative image of the decorative stencil can be applied. Specifically, for example, as is known from positive or negative staining of wood-based materials, the color impression of texture can be reversed using digital data, thereby obtaining negative results regarding color or, in particular, lighter and darker areas. This is possible not only for color impressions but also for the applied structure, thus enabling the achievement of negative effects in structural design. Such effects can also be easily integrated into production processes based on digital 3D data without the need for lead time or conversion.

[0107] In a preferred embodiment of this method, the shaping in step d) can be performed using at least one main roller pair, which consists of two rollers with large diameters and at least three shaping rollers arranged sequentially with diameters smaller than those of the main roller pair. To obtain the most uniform surface structure possible for receiving decoration, it has proven particularly advantageous to apply mechanical force, and if necessary, thermal force to the carrier in a non-uniform manner using different roller sizes. This measure results in a particularly smooth carrier surface, which can be decorated particularly easily and reproducibly. Here, the main portion of the desired and necessary deformation can be achieved using a larger roller pair, while another smaller shaping roller applies only a smaller force to obtain a uniform shaped product and delivers air out of the substrate in a controlled manner. This allows for high linear speeds while maintaining only slight thickness variations in the produced carrier. Roller diameters are dimensionally different if the corresponding diameters of the main rollers and shaping rollers differ by at least 10%. For example, the above-described components result in the following roll gap assembly for molten polymer material: The molten polymer material is forced through the roll gaps between the main rollers and at least two roll gaps between at least three shaping rollers. For example, the component may have a total of 8, preferably 6, and more preferably 4 shaping rollers. It has been found that this number of individual roller gaps is particularly suitable for obtaining decorative panels with improved surface and decorative properties.

[0108] In another embodiment of the method, the height of the shaping roll gap between the main roller and the shaping roller (HH) can differ from the height of the shaping roll gap between the main roller and the shaping roller (HK) by greater than or equal to 10% and less than or equal to 50%. This ratio of roll gap height between the main roller and the shaping roller has proven particularly suitable for obtaining a particularly smooth carrier surface and a carrier material with particularly low mechanical stress. The forces acting on the carrier can be determined collectively by this specification, thereby specifying a force distribution particularly suitable for the production of decorative panels for the roller assembly. This results in particularly advantageous performance regarding the presence of air inclusions and the occurrence of stress cracks in the carrier material. Furthermore, the distance of the applied mechanical force for forming the carrier relative to the location where the decoration is applied also appears to play an important role. In this regard, it has been found particularly suitable in preferred embodiments that the height of the shaping roll gap is greater than or equal to 10% and less than or equal to 50% of the height of the main roller roll gap. This allows for higher linear speeds without sacrificing the surface quality of the decorative panel.

[0109] In another aspect of the method, the height of the last and / or penultimate shaping roll gaps can be selected such that the carrier is compressed at its height by a coefficient less than or equal to 10% and greater than or equal to 3%. This compression ratio has proven particularly advantageous for obtaining exceptionally low air retention and a exceptionally smooth carrier surface. This ratio can be determined, for example, by measuring the substrate thickness before and after passing through the roll gaps. Here, the desired compression ratio is adjusted either by the shaping roll gap height ratio or also by the force applied to each roll gap.

[0110] In another preferred embodiment of the method, in addition to the main roll pair, the roll assembly may include at least four additional shaping rolls, wherein one of the shaping roll gaps is driven isobarically. Compared to an operating mode with a constant gap thickness between the shaping rolls, it has proven particularly advantageous for the surface properties of the carrier that at least one of the roll gaps operates isobarically, i.e., acts on the carrier with a constant force. This allows for very fast processing times while maintaining the smoothest possible carrier surface. In the sense of the invention, isobaric operation means that, by controlling the roll gap, the force fluctuation acting on the carrier in the roll gap during carrier production is less than 10%, preferably less than 5%, and more preferably less than 2.5%. The force used to produce the carrier can be measured, for example, by force sensors in or on the rolls, or by one or more force sensors in the carrier material.

[0111] In a preferred aspect of the method, the master roll and the shaping roll can be configured to be temperature-controlled, and the temperature-controlled surface area of ​​the shaping roll can be greater than or equal to 1.1 to less than or equal to 2.5 times that of the master roll. In addition to the mechanical treatment of the molten polymer block, the roll assembly can also be used for the simultaneous heat treatment of the carrier. Heat treatment can, in principle, include partial heating or partial cooling of the carrier. Advantageously, the molten material is cooled at the surface of the rolls. This can be achieved, for example, by providing a supply device for a heat transfer medium, such as a coolant, internally on each roll. It is also advantageous that the surface temperature of each roll in the roll assembly can be controlled individually. This can contribute to a particularly reproducible and gentle forming and cooling process. The aforementioned ratio of cooling surfaces between the master roll and the shaping roll has proven particularly suitable for obtaining decorative panels with particularly low mechanical stress and particularly little air inclusion. Without being bound by theory, higher quality decoration is achieved by heat dissipated in a controlled manner in each step, which is also proportional to the surface area of ​​the roll pair. Within this range, very high web speeds and particularly efficient removal of air inclusions from the carrier can also be achieved. Furthermore, the temperature of each roller can be selected based on the mechanical force applied to the carrier, and thus the cooling rate that can be obtained can also be selected. For example, a greater force caused by the high compression of the carrier material can be accompanied by a higher temperature gradient between the roller and the carrier material, thereby obtaining a carrier with lower overall mechanical stress.

[0112] Preferably, the method may include the following steps: e) applying a thin film to at least a portion of the sealable layer of the plate-like carrier. This can further improve the plate-like carrier to obtain its desired properties, particularly optical and tactile properties.

[0113] In one embodiment, the method may be specified to include multiple method steps (e). Therefore, it may be specified that multiple films are applied to at least a portion of the sealable layer of the plate-like carrier in the method. Furthermore, it may be specifically specified that the first applied film contacts the sealable layer, and each subsequently applied film correspondingly contacts the previously applied film.

[0114] Preferably, the film comprises at least one covering layer, wherein the covering layer preferably comprises an inner side, an outer side, and optionally a decorative layer applied to the inner side of the covering layer, wherein the film is applied to the sealable layer such that the outer side of the covering layer faces away from the plate-like carrier. Thus, the plate-like carrier can be decorated particularly simply and effectively.

[0115] In particular, if no decoration is applied to the sealable layer of the carrier plate in the method, the film may contain a decorative layer.

[0116] Preferably, the cover layer comprises a fourth polymer, wherein the fourth polymer is a vinyl polymer, and preferably the cover layer is substantially composed of the fourth polymer, wherein the third vinyl polymer may be a homopolymer or a copolymer, wherein the vinyl polymer preferably comprises a polypropylene-based vinyl polymer, particularly preferably comprises a polypropylene copolymer, which is preferably selected from propylene-ethylene random copolymers, propylene-ethylene block copolymers and polypropylene-ethylene-butene copolymers.

[0117] Preferably, the covering layer has a multilayer structure composed of different vinyl polymers.

[0118] Preferably, the thickness of the covering layer is in the range of greater than or equal to 10 μm to less than or equal to 1000 μm, more preferably in the range of greater than or equal to 50 μm to less than or equal to 750 μm, and particularly preferably in the range of greater than or equal to 100 μm to less than or equal to 500 μm.

[0119] It can be demonstrated that such a coating is particularly well suited to the above method because it has good abrasion resistance on the one hand and can be easily processed and can have a correspondingly applied decoration on the other hand.

[0120] In a preferred embodiment, the capping layer of the film may be specified to include a surface texture. Therefore, texturing of the capping layer can be omitted in other methods. Thus, the method can be applied with particular flexibility.

[0121] Advantageously, the decorative layer may be specified to have a decoration that replicates the decorative stencil. Here, the decoration can be applied by so-called direct printing. In the sense of this invention, the term "direct printing" is understood as applying the decoration directly to the inside of the overlay layer. Different printing techniques can be used, such as flexographic printing, offset printing, or screen printing. In particular, inkjet or laser printing processes can be used as digital printing techniques. Specifically, it may be preferably specified that the decoration is produced by flexographic printing in roll-to-roll digital printing, gravure printing, or counter printing processes.

[0122] Preferably, the decorative layer comprises a heat-sealable printable ink. Specifically, in the context of this invention, heat-sealable printable ink is understood as a laminable ink. For example, the laminable ink may be specified to contain a radiation-curable ink, preferably ≥50 wt% to ≤99 wt%, preferably ≥70 wt% to ≤95 wt%, particularly preferably ≥80 wt% to ≤90 wt%, and the laminable ink may contain a heat-activated matrix material, preferably ≥1 wt% to ≤50 wt%, preferably ≥5 wt% to ≤30 wt%, particularly preferably ≥10 wt% to ≤20 wt%, wherein the matrix material comprises at least one heat-activated polymer, preferably ≥1 wt% to ≤30 wt%, preferably ≥5 wt% to ≤20 wt%, particularly preferably ≥10 wt% to ≤15 wt%.

[0123] This allows for the elimination of laminating adhesives or laminates.

[0124] In a preferred embodiment, the film may be specified to include a laminated layer, wherein the laminated layer is preferably applied to the inside of the overlay decorative layer, and wherein the laminated layer is particularly preferably bonded to the decorative layer by a lamination adhesive. This allows the decorative layer to meet fewer specific requirements.

[0125] Preferably, the laminate comprises a fourth vinyl copolymer, preferably a vinyl terpolymer, more preferably a polypropylene vinyl copolymer, and particularly preferably a polypropylene-ethylene-butene copolymer.

[0126] Preferably, the fourth vinyl copolymer can be defined as the third vinyl copolymer. In particular, it can be preferably defined that the fourth vinyl copolymer and the third vinyl copolymer are the same.

[0127] In an alternative, preferred embodiment, the film does not include a laminate. This allows for simple film manufacturing.

[0128] It may be preferably specified that the film is applied during the setting process in step d), wherein the film is preferably applied after the first pair of rollers, preferably before the sixth setting roller, more preferably before the fifth setting roller, particularly preferably before the fourth setting roller, and particularly preferably before the third setting roller.

[0129] Therefore, it is possible to achieve, on the one hand, excellent adhesion of the film to the plate-like carrier during shaping, and on the other hand, to minimize the need for special temperature control of the plate-like carrier. Consequently, the method is particularly simple and inexpensive.

[0130] In an alternative, preferred embodiment, the film may be applied in method step d) after shaping, preferably using a calender following the shaping step. Thus, this method step can be mechanically decoupled from the preceding method steps. The plate-like carrier may also retain residual temperature, thereby saving energy. Simultaneously, the mechanically decoupled execution of the method steps allows for particularly simple process control.

[0131] Preferably, the film is provided in roll form. For this purpose, it is preferably specified that the film is provided within an unwinding station, which is preferably equipped with an automatic edge-guiding device. Preferably, the unwinding station is redundantly constructed, thereby providing the film with automatic roll changing at the end of each film roll, wherein in particular, an automatic splicing process occurs at the end of the film roll and the beginning of a new film roll.

[0132] Preferably, multiple films are applied parallel to each other across the width of the plate-like carrier, with the unwinding station being particularly a double unwinding station. This method is particularly suitable for very wide plate-like carriers because it simplifies process control.

[0133] Preferably, the film is preheated before being applied to at least a portion of the sealable layer of the plate-like carrier, preferably to a temperature range greater than or equal to room temperature and less than or equal to 160°C, more preferably to a temperature range greater than or equal to 50°C and less than or equal to 155°C, and particularly preferably to a temperature range greater than or equal to 125°C and less than or equal to 145°C. This allows for better adhesion of the film to the plate-like carrier.

[0134] It may be preferably specified that the preheating of the thin film is achieved by electromagnetic radiation, particularly by using radiation in the infrared and / or near-infrared range.

[0135] Preferably, when the film is applied, the sealable layer of the plate-like carrier has a temperature in the range of 105°C to 160°C, more preferably 110°C to 140°C, more preferably 115°C to 130°C, and particularly preferably 120°C to 125°C. This allows for better adhesion of the film to the plate-like carrier.

[0136] It can be preferably specified that the film is applied at a temperature below the melting point of the second polymer block.

[0137] Preferably, the method includes another step f), namely, structuring the overlay, wherein the overlay is preferably achieved using the texture rollers of a calender. This allows the overlay to have a particularly comfortable feel, thereby leaving a particularly valuable impression.

[0138] Preferably, patterning is performed in step d) after shaping, and more preferably immediately after shaping. This allows for the elimination of the need for special temperature control. Furthermore, it allows for the elimination of the need for reheating of the plate-like carrier or covering layer.

[0139] Preferably, the patterning provides the covering layer with an overall structure. This structure proves particularly suitable for the method described above, as no special coordination between the decoration and the structure is required.

[0140] It may be preferably specified that patterning is performed at the temperature when the sealable layer smaller than the plate-like carrier is coated with a thin film. It may be preferably specified that patterning is performed at a temperature in the range of 60°C to 140°C, preferably in the range of 80°C to 120°C, and particularly preferably in the range of 90°C to 110°C.

[0141] In another step, the decorated carrier sheet can then be divided into individual panels using a suitable mechanical process. This can be done, for example, by cutting the extruded strands at regular intervals or at regular time intervals. Preferably, this method step can produce cut panels of equal length.

[0142] Furthermore, according to the present invention, an apparatus for producing decorative wall or floor panels is provided, wherein the apparatus includes means for performing the method according to the present invention.

[0143] For the advantages of the apparatus according to the invention, reference is made explicitly to the advantages of the method according to the invention. A preferred embodiment of the apparatus, for providing molten polymer blocks, may include a temperature-controlled screw extruder.

[0144] Preferably, the device includes a feed block and a multi-channel nozzle, particularly the feed block. More preferably, the device includes a variable profile wide-mouth nozzle.

[0145] Furthermore, the equipment may include temperature-controlled and, in particular, coolable rollers. During production, the individual rollers can move relative to each other in their positions, thus changing the size of the gap formed between the rollers. Preferably, at least one larger pair of master rollers and multiple, preferably at least three, more preferably four, and more preferably five, smaller shaping rollers can be used to form and shape the carrier. The rollers can be configured to be individually adjustable in terms of their temperature.

[0146] The equipment may also include additional means for final cooling of the carrier. It may also include additional means for recirculating heat dissipated from the carrier back into the product cycle. This can be accomplished, for example, via a heat exchanger. The recovered waste heat can be used, for example, for temperature control of the extruder. Furthermore, the equipment may include additional means for machining the carrier, such as special shaping for the carrier edges. Additionally, the equipment may include additional means for further dividing the extruded sheet into smaller panels of substantially equal length. This division or cutting can be performed, for example, by using a saw. For this purpose, a circular saw or band saw, for example, may be suitable. However, other physical methods, such as lasers, can also be used to divide the extruded and finished panels into smaller panels.

[0147] Furthermore, according to the present invention, a plate-shaped carrier for decorative walls or floors is produced by the method according to the present invention, the plate-shaped carrier comprising at least one carrier layer containing a first polymer block and at least one sealable layer containing a second polymer block in contact with the carrier layer.

[0148] For the advantages of the wall and floor panels according to the invention, reference is made to the advantages of the method according to the invention and the advantages of the device according to the invention.

[0149] In particular, it should be noted that by using the method according to the invention, panels can be obtained at very high linear speeds, characterized by exceptionally smooth surfaces and low air content in the pores and pores at the panel surface. The number and size of surface defects caused by air can be significantly reduced. Temperature control and mechanical processing also result in a very low-stress carrier. Furthermore, the method and apparatus are suitable for processing various materials.

[0150] Furthermore, according to the present invention, the wall or floor panels are produced by the method according to the present invention.

[0151] For the advantages of the wall and floor panels according to the invention, reference is made to the advantages of the method according to the invention and the advantages of the device according to the invention.

[0152] In particular, it should be noted that by using the method according to the invention, panels can be obtained at very high linear speeds, characterized by exceptionally smooth surfaces and low air content in the pores and pores at the panel surface. The number and size of surface defects caused by air can be significantly reduced. Temperature control and mechanical processing also result in a very low-stress carrier. Furthermore, the method and apparatus are suitable for processing various materials.

[0153] Other technical features and advantages of wall or floor panels are clearly described herein with reference to the methods, equipment and drawings.

[0154] The present invention will be further explained below with reference to the accompanying drawings and embodiments. Attached Figure Description

[0155] Figure 1 A cross-sectional view schematically illustrates the design of an apparatus for performing the method according to the invention;

[0156] Figure 2 A schematic plan view of an apparatus designed for performing the method according to the invention is shown.

[0157] Figure 3 The diagram schematically illustrates a roller assembly that guides molten polymer material through a shaping process.

[0158] Figure 4 The diagram schematically illustrates a roller assembly that guides molten polymer material through a shaping process.

[0159] Figure 5 The diagram schematically illustrates guiding molten polymer material through a shaping roller assembly with an amplified portion; and

[0160] Figure 6 A cross-sectional view schematically illustrating one manner of carrying out the method according to the invention is shown. Detailed Implementation

[0161] according to Figure 1 Equipment 1 is suitable for the method of producing decorative walls or floors. Figure 1A possible structure of an apparatus for producing decorative panel 1 is shown in cross-section, specifically illustrating a unit of extrusion equipment 2 with nozzles 5, main roller pairs 3, and shaping roller assembly 4. In this embodiment, six shaping rollers 7 are shown, each independently controllable in its X and Y positions. The possible order of rotation of the individual shaping rollers 7 is indicated by arrows. The apparatus 1 schematically shows the extrusion equipment 2, which is divided into an extruder (not shown separately) for heat-treating polymer particles and the actual nozzles 5, wherein the nozzles are multi-channel nozzles or optionally feed blocks (not shown) disposed between the extruder and the nozzles or multi-channel nozzles, through which the polymer blocks molten through the multi-channel nozzles are layered and stacked. The molten polymer strand exiting the nozzles is guided along with the individual main rollers 6 via the roll gap of the main roller assembly 3. The height of the roll gap between the two main rollers 6 can be variably adjusted by moving the main rollers 6 relative to each other. After the layered molten polymer blocks have undergone initial shaping and, if necessary, cooled through the roll gap of the main rollers, the strand is conveyed to the shaping roller assembly 4. In the shaping roller assembly 4, the height of the molten polymer strand is further reduced or shaped. This strand passes through the gap between the various shaping rollers 7, and its height varies as a function of the gap distance. Here, the various shaping rollers 7 do not always need to be equidistant from each other, thus allowing for different gap heights between them during the process. The shaping rollers 7 also do not need to have the same height, but can be offset from each other. This can alter the mechanical tensile properties of the molten polymer strand. After finishing by the main roller assembly 3 and the various shaping rollers 7, the shaped and flattened material can be decorated by a printing unit (not shown). Furthermore, the decorative surface of the panel can be provided with one layer, or, if desired, an additional layer, such as a protective coating.

[0162] Figure 2 A plan view of the apparatus 1 according to the invention is shown. The extrusion apparatus 2, shown, with an extruder and nozzles, conveys a molten strand of layered, stacked molten polymer to a main roll assembly 3. The distance between the main roll assembly 3 and the extrusion apparatus 2 is variable and can be changed, for example, by a controlled electric motor. After the molten polymer block has passed through the roll gap of the main roll assembly 3, the carrier, having changed height and optionally been slightly cooled by the main roll assembly 3, is guided into a shaping roll assembly 4. The shaping roll assembly 4 consists of individual shaping rolls 7, with a roll gap formed between them, through which the shaped carrier passes and is further shaped. The individual shaping rolls 7 can move integrally or separately in their relative positions. Furthermore, the roll surface temperature of each shaping roll 7 can be controlled integrally or individually.

[0163] Figure 3This illustrates a possible guidance of the molten polymer carrier 9 through the gap between the shaping rollers. For example, the molten polymer carrier 9 can be cooled by deposition onto the shaping rollers 7. In this assembly of individual shaping rollers 7, the thickness of the molten polymer carrier 9 is more likely to be altered by the mechanical tension of the rollers. The individual shaping rollers 7 are too far apart from each other to allow the molten polymer carrier 9 to be directly squeezed or compressed through the gap between the shaping rollers 7.

[0164] Figure 4 It shows the relationship with Figure 3 A similar shaping roller assembly 4 has two shaping rollers 7, wherein the shaping rollers 7 are closer together and form a gap smaller than the thickness of the molten polymer carrier 9. Since the molten polymer carrier 9 is at least partially thicker than the shaping roller gap, the height of the molten polymer carrier 9 is leveled by the shaping roller gap between the shaping rollers 7.

[0165] Figure 5 It was shown again Figure 4 The cross-section of the shaping rollers and an enlarged cross-section are shown. In the enlarged cross-section, it can be seen that excess material of the molten polymer carrier 9 is pushed upward at the beginning of the shaping roller gap. As a result, the height of the molten polymer carrier 9 is adapted to the height of the shaping roller gap. The height of the shaping roller gap can be adjusted by the distance between the shaping rollers 7, thereby adjusting the height of the carrier. According to the invention, it is advantageous that the shaping rollers 7 are so close that as little ambient air as possible can enter between the shaping rollers 7 and the molten polymer carrier 9. The narrow gap ensures that as little additional air as possible is forced into the carrier surface. The latter can help improve the shaped carrier surface.

[0166] Figure 6Another embodiment of the design of an apparatus 1 for producing decorative panels according to the present invention is shown. Apparatus 1 also includes an extrusion apparatus 2, such as having a grooved nozzle and an extruder. Molten polymer blocks are extruded through the nozzle and pass through the roll gap of the main roller 3 to a shaping roller assembly 4 comprising various shaping rollers 7. In this figure, it is shown that the various shaping rollers 7 do not necessarily have to be at the same height. For example, by deflecting the shaping rollers 7 in height, the mechanical forces and cooling performance in the air gap can be altered. Furthermore, the figure shows that a film 10 can be applied within the shaping roller assembly 4 comprising different shaping rollers 7, the film being, for example, available as a roll and applied at different locations within the shaping roller assembly 4. By applying the film 10 within the shaping roller assembly 4, the shaping rollers 7 can perform additional mechanical treatment on the layer, which can improve film adhesion to the carrier. Furthermore, this ensures that the application of the film 10 does not cause the carrier to deviate from the desired dimensions in height, since both the carrier and the film 10 pass through the final shaping roller gap. After the film 10 is applied, the carrier can be further tempered / cooled in a defined manner, or subjected to mechanical post-processing by an additional device 11. Suitable additional device 11 for this purpose may be a cooling or tempering surface or a mechanical milling machine for further shaping, such as the edges of the carrier.

[0167] Figure label:

[0168] 1 device

[0169] 2 Extrusion unit

[0170] 3 Main Roller Assembly

[0171] 4. Sterilizing Roller Assembly

[0172] 5 nozzles

[0173] 6 main rollers

[0174] 7. Setting rollers

[0175] 9. Molten polymer carrier

[0176] 10 films

[0177] 11 Other post-processing

Claims

1. A method for manufacturing decorative walls or floors, comprising the following steps: a) Provide a first molten polymer block and a second molten polymer block; b) Extruding molten polymer blocks, wherein each polymer block is extruded by a separate extruder, and the molten polymer blocks are layered and stacked; c) Discharges layered, stacked molten polymer blocks through nozzles; d) Molten polymer blocks stacked in layers are shaped to form a plate-like carrier, the plate-like carrier having a carrier layer comprising at least a first polymer block and a sealable layer comprising a second polymer block and in contact with the carrier layer, the shaping being performed by an assembly of multiple rotatable rollers; In step a), a third molten polymer block is also provided, and the plate-like carrier formed in step d) further includes at least one anti-tension layer comprising the third polymer block and in contact with the carrier layer.

2. The method of claim 1, wherein the first polymer block comprises a solid material, wherein the solid material comprises layered silicate powder.

3. The method of claim 1, wherein the first polymer block comprises a solid material, the solid material comprising talc.

4. The method of claim 1, wherein the second polymer block comprises a third polymer, wherein the third polymer is a vinyl copolymer.

5. The method of claim 4, wherein the vinyl copolymer comprises a vinyl terpolymer.

6. The method of claim 4, wherein the vinyl copolymer comprises a polypropylene-based vinyl copolymer.

7. The method of claim 4, wherein the vinyl copolymer comprises a polypropylene-ethylene-butene copolymer.

8. The method of claim 1, wherein the extruded molten polymer block results in a carrier layer having a plate-like carrier thickness of greater than or equal to 60% and less than or equal to 95%.

9. The method of claim 1, wherein the respective rollers are positioned above or behind each other, and each individual roller forms at least one shaping gap with an adjacent roller, wherein the adjacent rollers form a roller pair through which the layered stacked molten polymer blocks are guided, and wherein the height of the shaping gap can be variably adjusted during manufacturing by the horizontal and / or vertical movement of the respective rollers.

10. The method of claim 9, wherein the layered, stacked molten polymer blocks are guided through a plurality of roller pairs.

11. The method according to claim 1, wherein the method further comprises the step of: e) Apply the film to at least a portion of the sealable layer of the plate-like carrier.

12. The method of claim 11, wherein the film comprises at least one covering layer, wherein the covering layer comprises an inner side, an outer side, and optionally a decorative layer applied to the inner side of the covering layer, wherein the film is applied to the sealable layer such that the outer side of the covering layer faces away from the plate-like carrier.

13. The method of claim 12, wherein the cover layer comprises a fourth polymer, wherein the fourth polymer is a vinyl polymer.

14. The method of claim 13, wherein the vinyl polymer is a homopolymer or copolymer.

15. The method of claim 13, wherein the vinyl polymer comprises a polypropylene-based vinyl polymer.

16. The method of claim 15, wherein the vinyl polymer is selected from propylene-ethylene random copolymers, propylene-ethylene block copolymers, and polypropylene-ethylene-butene copolymers.

17. The method of claim 11, wherein the film comprises a laminate layer, wherein the laminate layer is applied on the inside of the cover decorative layer.

18. The method of claim 17, wherein the laminate is attached to the decorative layer by a laminating adhesive.

19. The method of claim 11, wherein the film is applied during the shaping process in step d).

20. The method of claim 19, wherein the film is applied after the first pair of rollers.

21. The method of claim 19, wherein the film is applied before the sixth shaping roller.

22. The method of claim 19, wherein the film is applied before the fifth shaping roller.

23. The method of claim 19, wherein the film is applied before the fourth shaping roller.

24. The method of claim 19, wherein the film is applied before the third shaping roller.

25. The method of claim 11, wherein the method further comprises step f), structuring the cover layer, wherein the cover layer is implemented by the texture roller of a calender.

26. A plate-shaped carrier for decorative walls or floors, manufactured by the method according to any one of claims 1 to 25, said plate-shaped carrier comprising a carrier layer containing at least a first polymer block and a sealable layer containing a second polymer block and in contact with the carrier layer.

27. A decorative panel, made by the method according to any one of claims 1 to 25.

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