Panel

Abstract

Panel for wall or ceiling cladding or floor covering, comprising a carrier layer (10) of HDF or MDF, onto which a decorative layer of plastic is applied, wherein the decorative layer (16) consists of a PVC-free and polyolefinic material, in particular PP or PET, with a wear layer (18) covering the decorative layer (16), which consists of PET or a polyolefinic transparent polymer, and with a damping layer (14) between the decorative layer (16) and the carrier layer (10), wherein the damping layer (14) consists of a wood-plastic compound material, and with a counter-tension layer (12) consisting of cork or polymer foam.

Description

[0001] The invention relates to a panel.

[0002] Such panels can be used, for example, as flooring. Laminate flooring is known from the prior art in which a decorative layer consisting of printed decorative paper and a top layer (overlay) is applied to a core board made of HDF / MDF. The underside of the core board is finished with a so-called backing layer made of plastic or impregnated paper.

[0003] In DE 20 2011 050 027 U1 such a panel is disclosed, in which an additional damping layer made of a granular material is provided, which is arranged between the carrier plate and the decorative layer.

[0004] Tongue-and-groove locking elements are formed on the longitudinal and end faces of such panels, allowing for horizontal and vertical locking of the panels (planks). By embossing the decorative paper and the aforementioned printing, the appearance of a parquet plank, for example, can be achieved.

[0005] One disadvantage of well-known laminate floors is that they only dampen impact sound to a limited extent, so additional impact sound insulation must be provided.

[0006] Flooring constructions that use plasticized PVC as a decorative and wear layer are becoming increasingly common. These products are either made of solid PVC or—similar to the laminate flooring described above—laminated onto an HDF / MDF core board. The advantage of these floors is that PVC is easy to work with, allowing for a relatively good imitation of wood characteristics. Another advantage is that the relatively soft PVC layer offers improved impact sound insulation compared to laminate flooring and is perceived by users as warmer and softer.

[0007] A disadvantage of such PVC flooring is that the plasticizers used in the PVC layer are emitted into the indoor air, and unavoidable abrasion dust from these materials is heavily contaminated with plasticizers. In poorly ventilated rooms with such PVC flooring, the permissible exposure limits can be exceeded many times over in unfavorable circumstances. Another problem is the disposal of PVC flooring in the event of renovation or remodeling. Currently, this disposal method is unclear. For example, in Germany, there is a ban on landfilling PVC materials. Incineration of PVC materials is also problematic, as special precautions must be taken to prevent damage to the waste incineration plant and the formation of highly toxic dioxins.

[0008] To overcome this disadvantage, the aforementioned DE 20 2011 050 027 U1 proposes to manufacture the wear layer and the decorative layer from a PVC-free material.

[0009] However, such panels have the disadvantage that they cannot withstand point loads.

[0010] In the publication DE 10 2006 052 555 C5 a method for manufacturing a panel is described in which a carrier board made of a WPC material is used instead of an HDF / MDF carrier board.

[0011] In contrast, the invention is based on the objective of creating a panel that is improved with regard to damping and load-bearing capacity.

[0012] This problem is solved with regard to the panel by the features of claim 1.

[0013] Advantageous further developments of the invention are the subject of the dependent claims.

[0014] According to the invention, the panel for wall or ceiling cladding or for flooring has a carrier layer or carrier board onto which a "soft" decorative layer made of plastic is applied. According to the invention, this decorative layer consists of a PVC-free material, preferably a material approved for food packaging. Such materials are largely unproblematic from an environmental perspective and are therefore easy to dispose of, as both incineration and landfilling are possible, for example. Such materials can be modified with additives to have a soft, warm, and deeply textured character and are thus usable as a fully-fledged alternative to conventional PVC or laminate flooring.

[0015] The decorative layer consists of polypropylene (PP) in combination with an ionomer layer or of polyethylene terephthalate (PET). These materials are largely easy to process and can mostly be disposed of with household waste, without releasing any harmful toxins into the environment during landfilling, incineration, or other uses. These materials are also characterized by their extremely easy processing, thus simplifying panel production.

[0016] According to the invention, a damping layer made of WPC (wood-plastic composite) is formed between the decorative layer and the carrier layer.

[0017] A counter-tension layer is applied to the underside of the carrier layer. This counter-tension layer preferably consists of cork or polymer foam.

[0018] Wear resistance is improved because the embossed and possibly printed decorative layer is covered by a wear layer.

[0019] Such a wear layer is made of PET or a transparent polyolefinic polymer. To improve scratch resistance, these layers are sealed with a lacquer coating, for example, UV lacquer or PUR lacquer.

[0020] The carrier layer consists of HDF / MDF.

[0021] The WPC composite material can consist of a variety of layers, for example of tough-elastic polyolefin, a mixture of polyolefins and wood, or a mixture of polyolefins, in particular PP stone flour and wood, with individual layers being bonded together using a suitable adhesive, for example PUR.

[0022] In one embodiment of the invention, a stabilizing layer is provided beneath the decorative layer, thereby achieving improved pressure distribution, so that a floor constructed in this way reliably passes the "chair caster test". This stabilizing layer can, for example, be applied to or integrated into the damping layer.

[0023] In one embodiment of the invention, the stabilizing layer is made of glass fiber reinforced plastic, which is applied to the damping layer. Alternatively, glass fiber reinforced plastic fibers can also be incorporated into the damping layer as a matrix.

[0024] According to the invention, it is preferred if the decorative layer is designed as a wood imitation.

[0025] According to the invention, the decorative layer is sealed with a varnish.

[0026] Locking elements can be formed on the end and longitudinal edges to connect the panels, enabling horizontal and vertical locking.

[0027] According to a non-inventive method for producing such panels, a panel is first formed with a carrier layer and a decorative layer applied directly or indirectly to it. This panel has the dimensions X, Y, Z, wherein the decorative layer covers the area with dimensions X, Y.

[0028] After the carrier layer is laminated, the panel is cut into panels in the X direction, the width B of which corresponds approximately to the factor X / A (A = number of panels).

[0029] This method has the advantage that not every single panel is laminated, but a comparatively large panel is laminated, which is then separated into individual panels after lamination.

[0030] According to a further development of the process, a decoration of the decorative layer is repeated according to the number A of panels into which the panel is divided.

[0031] Preferred embodiments of the invention are explained in more detail below with reference to schematic drawings. These show: Fig. 1. a cut parallel to an end edge of a panel; Fig. 2 a highly simplified scheme to explain the manufacture of a panel according to the invention; Fig. 3 a plate from which several panels can be made according to Fig. 1. be trained; Fig. Figure 4 shows a section through an alternative version of a panel with a stabilizing layer; Fig. 5 shows a variant of a carrier layer and Fig. Figure 6 shows a plant configuration for producing a carrier layer according to Fig. 5.

[0032] Fig. Figure 1 shows a section parallel to an end edge of a rectangular panel 1, also called a plank. Such a panel 1 has a profile formed by milling along its longitudinal and end faces, which enables horizontal and vertical locking. The in Fig. The visible longitudinal edges 2, 4 are designed with a spring-like profile 6 and a groove-like profile 8, which can be connected to each other by angling them together, so that adjacent panels are locked together longitudinally in the horizontal and vertical directions. On the end faces, for example, so-called snap-fit ​​profiles can be used, which engage with each other when a panel to be installed is angled towards an already installed panel. Such snap-fit ​​connections can be provided with a spring element or a slider that can be moved from a release position to a locking position during installation. Such profile constructions are known from the prior art, so further descriptions are unnecessary.

[0033] The panel 1 according to the invention has a carrier layer 10, which is, for example, made of HDF board. The two profiles 6, 8 described above are also formed on this carrier layer 10 by milling.

[0034] A counter-tension layer 12, made of cork for example, is provided on the underside of the carrier layer 10.

[0035] On the usable side of the panel 1, a damping layer 14 is initially formed, which consists, for example, of cork or a suitable polymer foam. As explained above, this damping layer 14 can be provided with a stabilizing layer made of glass fiber reinforced plastic. This stabilizing layer can be applied to the damping layer 14 or incorporated into the damping layer as a matrix. In the embodiment according to Fig. 1. No stabilizing layer is provided.

[0036] A decorative layer 16, made of PET in the illustrated embodiment, is applied to the damping layer 14. This decorative layer 16 is designed by printing and embossing to imitate a wood structure, closely resembling the appearance of a natural product. As explained, such PET materials are very easy to dispose of, so the problem described earlier with PVC flooring does not exist.

[0037] Instead of a PET decorative layer, other suitable materials, though not in accordance with the invention, can also be used, such as those employed as packaging materials in the food industry or medical technology. PP or non-inventive ionomer films have proven particularly suitable alongside PET.

[0038] To minimize abrasion of the decorative layer, it is finished with a wear layer 18, which also consists of PET or a polyolefinic transparent polymer. Particles that minimize wear can be incorporated into the wear layer. Corundum particles have proven particularly suitable for this purpose.

[0039] The production of a panel 1 according to the invention is described using the Fig. 2 and Fig. 3 explained.

[0040] Fig. Figure 2 shows a highly simplified process diagram for manufacturing such a panel. A feed system 20 provides a carrier panel 22, which is made of HDF / MDF. This carrier panel is significantly larger than the panels to be manufactured. For example, a panel size (X,Y) of 2062 mm x 1250 mm can be used, with the dimensions of the finished panels then being 2045 mm x 235 mm.

[0041] The carrier board 22 is fed via the feeding station 20 to a gluing station 24, where the carrier board 22 is coated on its upper and / or lower surface with an adhesive layer, for example, polyurethane. This adhesive layer is applied via an application roller 26. The carrier board 22, coated with one or two adhesive layers, is then fed to a laminating unit 26, where the cork layer, the decorative layer, and the wear layer are applied. The individual layers can each be applied by a separate lamination process. However, it is simpler to form the three layers (damping layer, decorative layer, and wear layer) using a film composite, so that a single lamination process is sufficient. Such an embodiment is shown in Fig. 2 indicated. The film composite is rolled over a laminating roller 28 (calender) and forms a strong bond with the substrate 22 via the adhesive. The film is unwound from a supply roll 30. After the film is bonded to the substrate 22, the blank is fed to a singulation station 32, where the laminated substrate 22 is cut lengthwise.

[0042] Fig. Figure 3 shows a top view of the laminated carrier plate 22 after the lamination station 26. Accordingly, the decorative printed image 34 is in the longitudinal direction of the carrier plate 22 (horizontal in Fig. 3) printed across the entire width Y of 1250 mm, with the decorative print image 34 repeating according to the number A of panels into which the carrier plate 22 is divided. In the specific embodiment, the decorative image 34 repeats five times, with the decorations arranged alternately in opposite directions along the longitudinal axis, i.e., offset from each other by 180°. The lamination direction is thus longitudinal with the decoration direction, with the width of the calender 28 corresponding to the film width. The lamination direction is in Fig. 3 is indicated by an arrow. The surface is also embossed via the laminating roller, further enhancing the wood-like appearance. In the singulation station 32, the relatively large carrier panel 22 is then cut into five panels measuring 2045 mm x 235 mm, according to the applied decor, and the previously described profiling 6, 8 is formed on the end and longitudinal sides. The plastic waste generated during production can be recycled without major problems and thus reused.

[0043] In Fig. Figure 4 shows another embodiment of a panel with a soft surface.

[0044] The basic structure of the in Fig. The embodiment shown in Figure 4 largely corresponds to the embodiment described above. One difference is that in this variant, the aforementioned stabilizing layer 36 is formed below the damping layer 14. As explained, this stabilizing layer 36 can be located on the carrier layer or on the underside (view according to Figure 4). Fig. 4) be formed in the damping layer 14. In principle, it is also possible to incorporate this stabilizing layer as a matrix into the damping layer 14.

[0045] In the specific embodiment, the stabilizing layer 36 is formed by a reinforcing fabric or scrim made of plastic, preferably fiber-reinforced plastic.

[0046] The carrier layer 10 can, for example, be made of HDF / MDF material for use in residential areas. Alternatively, but not according to the invention, other materials can of course also be used for the carrier layers. For example, for use in wet areas, a carrier layer made of a so-called WPC material (wood-plastic composite) is used. Such wood-plastic composites are well known. In principle, carrier layers made of pure plastic or layered structures can also be used. For example, the carrier layer can consist of materials such as wood, PP, or stone flour, which are bonded together via a PUR adhesive.

[0047] The decorative layer consists, for example, of PET, while the wear layer 18 may also be made of PET, another polyolefin and / or be coated with a lacquer layer.

[0048] The damping layer 14 can consist of non-inventive tough-elastic polyolefin, WPC (PP-wood), non-inventive cork-PP-wood, or a non-inventive plastic layer. The counter-tension layer 12 can also be made of these materials.

[0049] As mentioned, the carrier layer 10 can also be multi-layered. Such a structure is found in Fig. Figure 5 shows a carrier layer 10 consisting of a plurality of layers 10a, 10b, 10c, each bonded by an adhesive layer 38, for example of PUR or another, preferably elastic, adhesive. This layer structure can then be applied as shown in Fig. 5 indicates that the counter-tension layer 12 and / or the damping layer 14 are applied to the underside.

[0050] Fig. Figure 6 shows the production of the carrier layer 10 according to Fig. 5. First, the individual layers 10a, 10b are loaded into a loading station 38, and glue is applied in a gluing station 40. Several of the layers 10a are then stacked into a stack 42 using a device (not shown), with a layer of glue between each pair of adjacent layers. The stack 42 is pressed in a pressing station 44, causing the glue to harden and creating a high-quality bond between the individual layers 10a, 10b, 10c. In a subsequent step, the carrier layer 10 is finely machined and brought to size, so that further processing can proceed as described above (see Fig. 3) can be done.

[0051] In principle, it is also possible to apply the stabilizing layer 36 during the production of this layer structure.

[0052] Profiles 6 and 8 can then be produced from the core by milling or similar processes. In principle, it is also possible to manufacture the profile from a different material and attach it to the support layer 10.

[0053] According to the invention, the entire panel consists of environmentally safe materials with neutral behavior in the ecological sense when disposed of. It has been shown that the aforementioned materials are sufficiently water-resistant for private use. They are soft, warm, durable, and the installed floor is also significantly quieter than laminate flooring.

[0054] Revealbart is a panel for wall or ceiling cladding or flooring with a carrier layer onto which a decorative layer made of a PVC-free material is applied. Reference symbol list: 1 panel 2 long side 4 Long side 6 spring-like profile 8 groove-like profile 10 carrier layer 12 counter-layer 14 Damping layer 16 decorative layers 18 Wear layer 20 Feeding station 22 Carrier plate 24 gluing stations 26 Laminating station 28 Laminating roller 30 rolls 32 isolation stations 34 Decorative print image 36 stabilization layer 38 Feeding station 40 gluing stations 42 stacks 44 Press station

Claims

[1] Panel for wall or ceiling cladding or floor covering, comprising a carrier layer (10) of HDF or MDF, onto which a decorative layer of plastic is applied, wherein the decorative layer (16) consists of a PVC-free and polyolefinic material, in particular PP or PET, with a wear layer (18) covering the decorative layer (16), which consists of PET or a polyolefinic transparent polymer, and with a damping layer (14) between the decorative layer (16) and the carrier layer (10), wherein the damping layer (14) consists of a wood-plastic compound material, and with a counter-tension layer (12) consisting of cork or polymer foam. [2] Panel according to claim 1, comprising a stabilizing layer provided below the decorative layer (16). [3] Panel according to claim 2, wherein the stabilizing layer is applied to or integrated into the decorative layer (16). [4] Panel according to claim 2 or 3, wherein the stabilizing layer consists of glass fiber reinforced plastic. [5] Panel according to one of the preceding claims, wherein the carrier layer (10) consists of a plurality of layers of the same or different structure glued together. [6] Panel according to one of the preceding claims, wherein the decorative layer (16) is designed as a wood imitation. [7] Panel according to one of the preceding claims, with locking profiles formed on the front and side edges.

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