Floor, ceiling or wall element

Abstract

Floor, ceiling or wall element (10; 11), comprising at least one cover layer (12) with an organic substance, a carrier plate (14) made of wood, to which the cover layer (12) is fastened, wherein the cover layer (12) contains cracked nutshells (N) or consists of such cracked nutshells (N), the cracked nutshells (N) having a specific volume of at least 2,500 cm3 / kg, and wherein the cover layer (12) contains at least one binding agent with which the cracked nutshells (N) are held together.

Description

[0001] The invention relates to a floor, ceiling or wall element.

[0002] According to the prior art, it is generally known to produce elements for covering floors or walls with at least one covering layer or decorative layer made of an organic substance or natural material in the form of wood, see DE 198 06 136 A1, DE 198 52 035 A1, or DE 102 45 914 B4. In particular, wooden floor elements for parquet are known, which is a wooden floor covering for rooms in enclosed buildings.

[0003] WO 2007 / 043955 A1 discloses a wood-based flooring material and contains on page 4 of the description (lines 10-11) an indication that a backing surface has a coating of a thermoplastic composition which may consist of nutshell flour.

[0004] The wooden floor elements mentioned above use a top or decorative layer, which is usually made of high-quality wood and is therefore expensive.

[0005] DE 20 2011 001 628 U1 shows a floor element in the form of a sealing element, comprising a cover layer in the form of a decorative layer with an organic material, and a wooden carrier plate to which the cover layer is attached. Decorative elements, such as nutshells, are embedded in the decorative layer. Furthermore, the cover or decorative layer contains a binding agent that holds the nutshells together.

[0006] Accordingly, the invention is based on the object of creating a floor, ceiling or wall element whose covering layer can be realized more inexpensively and in particular using natural or organic materials.

[0007] The above object is achieved by a floor, ceiling, or wall element having the features of claim 1. Advantageous developments of the invention are defined in the dependent claims.

[0008] A floor, ceiling, or wall element according to the present invention comprises at least one cover layer with an organic material and a wooden support plate to which the cover layer is attached. It is characteristic of the present invention that the organic material of the cover layer has the form of cracked nutshells. This means that the cover layer contains cracked nutshells or consists of such cracked nutshells. The cracked nutshells have a specific volume of at least 2,500 cm 3 / kg. The top layer contains at least one binding agent that holds the cracked nutshells together.

[0009] The invention is based on the essential finding that cracked nutshells are used to produce the top layer. Such an organic or natural substance is generally not used in the production of building materials, so in this respect, the present invention addresses the aspect of sustainability in the production of building materials.

[0010] With regard to the term "cracked," it should be specifically noted that, for the purposes of the present invention, this is a synonym for "broken" or "cracked." This means that "cracked nutshells" are those that have been broken or cracked.

[0011] Cracked nutshells advantageously have a larger specific volume than powdered or ground nutshells. This makes it comparatively easy to produce an inherently stable molded body, preferably using a matrix in the form of a suitable binder into which the cracked nutshells are incorporated or embedded, which in this case forms the said covering layer for a floor, ceiling, or wall element according to the invention. Another advantage here is that a characteristic pattern corresponding to the cracked nutshells is formed on an outer surface of the covering layer, particularly if the covering layer is sanded off on this outer surface after the binder has hardened or solidified, to create a flat or level surface.

[0012] Based on the fact that the cover layer, as just explained, contains at least one binder with which the cracked nutshells are held together, such cohesion of the cracked nutshells is achieved, for example, by suitably embedding these nutshells in the binder and then holding them together after the binder has cured or set. For example, said binder can be formulated based on an epoxy resin, which is processed in conjunction with a suitable hardener.

[0013] Considering that the cracked nutshells have a specific volume of at least 2,500 cm 3 / kg, it is pointed out at this point for a better understanding of the invention that nutshells in ground form usually have only half the specific volume, for example about 1,200 cm 3 / kg. This means that for the purposes of the present invention, cracked nutshells are used to produce the cover layer of a floor, ceiling, or wall element according to the invention, which nutshells have a specific volume that is more than twice as large as the ground form.

[0014] In connection with the specific volume of the cracked nutshells, which according to the invention as explained is at least 2,500 cm 3 / kg, and the resulting size of the pieces of the cracked nutshells, it should also be noted at this point that, thanks to this, the covering layer, in which these cracked nutshells or the pieces thereof are held together in conjunction with the binding agent, already possesses considerable inherent stability. This has a particularly advantageous effect when the invention is used as a floor element, making it resistant to impacts or damage, thus advantageously leading to a long service life.

[0015] In an advantageous development of the invention, the cracked nutshells can have a specific volume of at least 2,600 cm 3 / kg, preferably at least 2,700 cm 3 / kg, more preferably of at least 2,800 cm 3 / kg, more preferably of at least 2,900 cm 3 / kg, more preferably of at least 3,000 cm 3 / kg, more preferably of at least 3,100 cm 3 / kg, more preferably of at least 3,200 cm 3 / kg, more preferably of at least 3,300 cm 3 / kg, more preferably of at least 3,400 cm 3 / kg, and more preferably of at least 3,500 cm 3 / kg.

[0016] To produce the cover layer and / or an intermediate layer for a floor, ceiling or wall element according to the invention, various types of nuts can be used, e.g. walnuts, hazelnuts, pistachios or almonds.

[0017] For example, according to an advantageous development of the invention, the cracked nutshells may be made of hazelnut. In this case, the cracked nutshells have a specific volume of approximately 3,000 cm 3 / kg.

[0018] According to an alternative development of the invention, the cracked nutshells may be made of pistachios. In this case, the cracked nutshells have a specific volume of approximately 3,300 cm 3 / kg.

[0019] In an advantageous development of the invention, the outer surface of the cover layer can be provided with a seal. Such a seal can expediently be formed from polyurethane / polymer sealing varnish and / or an oil and / or a hard wax. This ensures that after sanding the outer surface of the cover layer, the open pores of the cracked nutshells are resealed, thus providing effective and long-lasting protection against possible penetration of water, moisture, and / or dirt.

[0020] According to one possible embodiment of the floor, ceiling, or wall element according to the invention, it consists solely of its cover layer, which, as explained above, contains cracked nutshells or is formed from such cracked nutshells. To improve the rigidity of such an embodiment of a floor, ceiling, or wall element according to the invention, fiber elements can be integrated or incorporated into the cover layer. Such fiber elements can expediently consist of hemp fibers, glass fibers, and / or carbon fibers. Such fiber elements can be designed either as short fiber elements or in an elongated form.In the latter case, according to an advantageous development of the invention, it can be provided that these elongate fiber elements are assigned to at least two different groups, wherein the elongate fiber elements of the individual groups are arranged oriented at an angle compared to the elongate fiber elements of a respective other group, preferably that the elongate fiber elements of two groups are each arranged orthogonally to one another.

[0021] Particularly in the case where a floor, ceiling, or wall element according to the invention consists solely of a covering layer, an advantageous development of the invention can provide for a floor element with its covering layer to be applied directly to and secured to a screed layer. The adhesive bond between the covering layer and the screed layer then provides the covering layer with the required stability and strength. The same applies to a ceiling or wall element consisting solely of the covering layer, provided this covering layer is then applied to and secured to a ceiling or wall mortar layer.

[0022] According to the invention, the carrier plate, to which the cover layer is then attached, contributes to achieving improved stability of a floor, ceiling, or wall element. It is expedient to select the same external dimensions (i.e., width and length) for the carrier plate as those of the cover layer. Such a carrier plate has greater stability and rigidity in direct comparison to the cover layer, thus enabling the realization of a floor, ceiling, or wall element according to the invention in the form of a stable and robust molded body.

[0023] In an advantageous development of the invention, the carrier plate can be formed or manufactured from wood, in particular from MDF or HDF.

[0024] A particularly stable structure is achieved for the carrier board if it is made from glued multiplex boards.

[0025] In an advantageous development of the invention, it is also possible for the carrier plate to be made of drywall material, which is available on the market under the name “Aquapanel” ®.

[0026] Further advantageous aspects of the present invention are based on the following features: - Thermal insulation; - Improved impact sound and / or acoustic insulation, in particular in the case where the element according to the invention is used as a ceiling element; - Improved acoustic properties, namely by using a carrier plate with such improved acoustic properties; - Improved slip resistance on the surface of the top layer - this can also be achieved by a specific surface profile on the surface of the top layer; - When using the element according to the invention as a wall element, it can also be used as a plant wall; - The cracked nutshells can also be used for an intermediate layer of the floor, ceiling or wall element according to the invention.

[0027] It is understood that the features mentioned above and those to be explained below can be used not only in the combination specified in each case, but also in other combinations or on their own, without departing from the scope of the present invention.

[0028] The invention is schematically illustrated below using preferred embodiments in the drawing and is described in detail with reference to the drawing. In the drawings: Fig. 1 a perspective view of a floor, ceiling or wall element according to the invention according to a first embodiment, Fig. 2 a front view of the floor, ceiling or wall element of Fig. 1, Fig. 3 a cross-sectional view of the floor, ceiling or wall element of Fig. 1, Fig. 4 a perspective view of a support plate which is part of a floor, ceiling or wall element according to the invention according to a second embodiment, Fig. 5 a perspective view of a support plate which is part of a floor, ceiling or wall element according to the invention according to a third embodiment, Fig. 6 a perspective view of a floor, ceiling or wall element according to the invention according to the third embodiment, using a carrier plate of Fig. 4, Fig. 7 a front view of the floor, ceiling or wall element of Fig. 6, Fig. 8 a front view of a floor, ceiling or wall element in which a support plate of Fig. 5 is used, and Fig. 9 schematically shows a possible attachment of a floor element according to the invention to a screed layer or a possible attachment of a wall element according to the invention to a wall mortar layer.

[0029] Below, with reference to the Fig. 1-9, preferred embodiments of a floor element 10 according to the invention or of a wall element 11 designed in the same way are shown and explained, which is suitable for attachment to a screed layer E or to a wall mortar layer W (cf. Fig. 9). Identical features in the drawing are provided with identical reference symbols. It is specifically noted here that the drawing is merely simplified and, in particular, not to scale.

[0030] Fig. 1 shows a floor element 10 according to the invention according to a first embodiment. The perspective view of Fig. 1 illustrates that this floor element 10 is designed in the form of an elongated rectangle.

[0031] The floor element 10 according to the embodiment of Fig. 1 comprises a cover layer 12, which in this case consists of cracked nutshells.

[0032] To produce the floor element 10 according to its shape of Fig. 1 cracked nutshells, for example with a specific volume of at least 2,500 cm 3 / kg, in a corresponding tool mold (not shown), preferably with a suitable binder. After the binder has hardened or set, the cover layer 12 can be removed from the said tool mold. Following this, grinding of the cover layer on its upper outer surface 12A can be provided in order to achieve an exactly flat or level surface. By such grinding, the appearance of the cover layer 12 is achieved to the characteristic pattern, as shown in Fig. 1 can be seen.

[0033] Following sanding of the outer surface 12A of the top layer 12, it may be provided with a sealant. A suitable oil or hard wax can be used for this purpose.

[0034] The shaped body of the floor element 10 according to Fig. 1 is in the Fig. 2 shown again in a front view.

[0035] Fig. 3 shows the floor element 10 of Fig. 1 again in a cross-sectional view. This shows that, due to the cracked nutshell composition, the nutshells are also present inside the base element 10, and not just on its outer surface 12A.

[0036] With regard to the first embodiment of a floor element 10 according to the Fig. 1-3, it should be pointed out that this floor element 10 consists solely of the said cover layer 12. A summary of the Fig. 1-3 illustrates that such a cover layer 12 has a sufficient thickness to assume sufficient stability in itself.

[0037] To further improve the stability or rigidity, for the first embodiment of a floor element 10 according to the Fig. 1-3, it may be provided that fiber elements are incorporated or integrated into the cover layer 12. Such fiber elements can consist of hemp fibers, glass fibers, and / or carbon fibers. When a suitable binder is used, this binder not only bonds with the cracked nutshells embedded therein, but also with the aforementioned fiber elements. As a result, with such a composition of a floor element 10 according to the invention, an inherently more stable structural body can be realized, which is suitable for cladding floors or walls (cf. Fig. 9).

[0038] In the Fig. 4, Fig. 6 and Fig. 7 shows a second embodiment of a floor element 10 according to the invention and parts thereof.

[0039] In the second embodiment, the floor element 10 comprises a support plate 14, which in this case is formed from glued multiplex panels 16. The perspective view of Fig. 4 illustrates that such a carrier plate 14 has the same dimensions as the cover layer according to Fig. 1. As is known, multiplex panels 16 have a high degree of rigidity, so that they are well suited for forming a carrier panel 14.

[0040] In the second embodiment, a cover layer 12 is attached to the support plate 14 of the floor element 10 from above, as shown in the perspective view of Fig. 6. It is expedient here that the dimensions of the carrier plate 14 and the cover layer 12 (in width and length) correspond to one another and insofar as the cover layer 12, when it is fastened or glued to the carrier plate 14 from above, forms a shaped body together with the carrier plate 14, in the embodiment shown here in a rectangular shape.

[0041] The second embodiment of the floor element 10 according to the invention is characterized in comparison to the first embodiment of Fig. 1 is characterized by improved stability, which is achieved by the carrier plate 14 and its properties. In this context, with regard to the cover layer 12 of the second embodiment, it should be noted that its thickness is greater than that of the first embodiment (cf. Fig. 1-3) is chosen lower. This is also reflected, for example, in the Fig. 7, which is a front view of the molded body of Fig. 6 shows.

[0042] In the same way, in the second embodiment (cf. Fig. 6) of the floor element 10 according to the invention, it can be provided that an outer surface 12A of the cover layer is ground. In addition to creating a perfectly flat surface for this outer surface, this also has the effect of making the structuring of the cracked nutshells visible on this outer surface 12A.

[0043] According to a third embodiment of a floor element 10 according to the invention, a carrier plate 14 (cf. Fig. 5) may be provided, which is made of drywall material, for example of the material "Aquapanel" ®. In this case, a cover layer 12 can be attached to the top of such a carrier plate 14, as shown in the end view for such a third embodiment according to the Fig. 8.

[0044] The third embodiment of the floor element 10 (cf. Fig. 5, Fig. 8) has the same advantage as the second embodiment that, thanks to the carrier plate 14, improved stability and rigidity is achieved for the cover layer 12 attached thereto.

[0045] According to a modification or alternative, for the third embodiment of Fig. 5 or Fig. 8, the support plate may be made of wood, for example, MDF or HDF material. In this case, the aforementioned advantages regarding the stability achievable for the support plate 14 or the floor element 10 realized with it remain unchanged.

[0046] For the second embodiment (cf. Fig. 4, Fig. 6, Fig. 7) and the third embodiment (cf. Fig. 5, Fig. 8) of the floor element 10 according to the invention, it should be pointed out separately at this point that the associated cover layer 12 is produced in the same way as in the Fig. 1-3 shown and explained. If necessary, the thickness of the cover layer 12 may be different compared to the first embodiment (cf. Fig. 1-3) is chosen to be lower, as can be seen from the front view of Fig. 7 or Fig. 8. In any case, for the second embodiment (cf. Fig. 4, Fig. 6, Fig. 7) and the third embodiment (cf. Fig. 5, Fig. 8) of the floor element 10 according to the invention, it is also provided that the associated cover layer 12 contains or consists of cracked nutshells, said cracked nutshells having a specific volume of at least 2,500 cm 3 / kg.

[0047] The floor element 10 explained above can be used to line a floor or a floor surface, preferably in a plurality of ways, and in this case, as shown by the symbolic representation of a room R of Fig. 9, are applied to a screed layer E of room R and secured thereto. In this case, the floor elements 10 are then placed flat next to each other on the screed layer E and secured thereto.

[0048] The aforementioned lining of a floor surface can be achieved with all three of the described floor element embodiments. With regard to the first embodiment, it should be noted that the covering layer 12 is applied directly to the screed layer E and secured thereto.

[0049] The present invention can be used in the same way for lining a wall surface W. In this case, the said floor element 10 then has the function of a wall element 11, which in its shape and composition corresponds in the same way to the three previously explained embodiments of a floor element. Fig. 9 symbolically indicates for a room R that such a wall element 11 can be applied to a wall surface W and attached thereto.

[0050] With regard to the lining of a floor area of a room R, it should be noted that in the course of the present invention this can be done not only with already prepared individual floor elements 10 according to the embodiments of Fig. 1-8 is possible, but that this can also be achieved by loosely applying cracked nutshells to a screed layer E. In this case, it is possible for the cracked nutshells, after they have been applied to the screed layer E, to then be provided with a binder or poured, wherein after the binder has hardened, the outer surface 12A of the cover layer 12 is then sanded. In this context, it is also possible to carry out suitable compaction for the cracked nutshells after they have been applied to the screed layer E, wherein this serves as a processing step for the surface design of the resulting cover layer.

[0051] With the aid of the present invention, it is possible—thanks to the use of cracked nutshells—to produce, for example, parquet flooring in a cost-effective manner. For this purpose, a plurality of the floor elements 10 according to the invention (cf. Fig. 1-8) are used, which are then applied next to each other on a screed layer E and attached to it.

[0052] Finally, it should be noted that the element according to the invention can also be used as a ceiling element. In this case, the cover layer 12 (cf. Fig. 1-3) is then applied directly to a ceiling mortar layer and fixed to it. List of reference symbols 10 floor element 11 Wall element 12 top layer 12A Outer surface (of cover layer 12) 14 Carrier plate 16 multiplex boards E screed layer N cracked nutshells W Wall mortar layer

Claims

[1] Floor, ceiling or wall element (10; 11), comprising at least one cover layer (12) with an organic substance, a carrier plate (14) made of wood, on which the cover layer (12) is fastened, wherein the cover layer (12) contains cracked nutshells (N) or consists of such cracked nutshells (N), wherein the cracked nutshells (N) have a specific volume of at least 2,500 cm 3 / kg, and wherein the cover layer (12) contains at least one binder with which the cracked nutshells (N) are held together. [2] Floor, ceiling or wall element (10; 11) according to claim 1, characterized by that the cracked nutshells (N) have a specific volume of at least 2,600 cm 3 / kg, preferably at least 2,700 cm 3 / kg, more preferably of at least 2,800 cm 3 / kg, more preferably of at least 2,900 cm 3 / kg, more preferably of at least 3,000 cm 3 / kg, more preferably of at least 3,100 cm 3 / kg, more preferably of at least 3,200 cm 3 / kg, more preferably of at least 3,300 cm 3 / kg, more preferably of at least 3,400 cm 3 / kg, and more preferably of at least 3,500 cm 3 / kg. [3] Floor, ceiling or wall element (10; 11) according to one of the preceding claims, characterized by that the cracked nutshells (N) from hazelnut with a specific volume of 3,000 cm 3 / kg are formed. [4] Floor, ceiling or wall element (10; 11) according to one of the preceding claims, characterized by that the cracked nutshells (N) from pistachios with a specific volume of 3,300 cm 3 / kg are formed. [5] Floor, ceiling or wall element (10; 11) according to one of the preceding claims, characterized by that the binder contained in the cover layer (12) is based on epoxy resin. [6] Floor, ceiling or wall element (10; 11) according to one of the preceding claims, characterized by that the cover layer (12) is provided with a seal on its outer surface (12A), preferably that the seal is formed from polyurethane / polymer sealing varnish and / or from an oil and / or from a hard wax. [7] Floor, ceiling or wall element (10; 11) according to one of the preceding claims, characterized by that preferably elongated fiber elements are integrated or incorporated into the cover layer (12) to improve its rigidity. [8] Floor, ceiling or wall element (10; 11) according to claim 7, characterized by that the fiber elements consist of hemp fibers, glass fibers and / or carbon fibers. [9] Floor, ceiling or wall element (10; 11) according to claim 7 or 8, characterized bythat the fiber elements are assigned to at least two different groups, wherein the elongate fiber elements of the individual groups are arranged at an angle compared to the elongate fiber elements of a respective other group, preferably that the elongate fiber elements of two groups are each arranged orthogonally to one another. [10] Floor, ceiling or wall element (10; 11) according to one of the preceding claims, characterized by that the carrier plate (14) on which the cover layer (12) is fastened is made of wood in the form of MDF or HDF. [11] Floor, ceiling or wall element (10; 11) according to one of the preceding claims, characterized by that the carrier plate (14) is formed from multiplex plates (16). [12] Floor, ceiling or wall element (10; 11) according to one of claims 1 to 9, characterized by that the support plate (14) is made of drywall material. [13] Floor element according to one of claims 1 to 12, characterized by that a surface of the cover layer (12) is provided with a specific surface profile in order to achieve slip resistance.

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