PLATE-SHAPED BUILDING ELEMENT

Description

[0001] The invention relates to a plate-shaped building element, in particular a floor panel.

[0002] Surface coverings, especially floor coverings, come in a wide variety of forms. Panel-shaped building elements are widespread, particularly floor panels in the form of laminate or parquet, with core boards made of compressed fibers. Resilient floor coverings are known as PVC coverings, linoleum coverings, or cork coverings.

[0003] Floor, wall, or ceiling panels, as well as similar sheet-like structures or panel bodies, are known in the prior art, inter alia, from DE 10 2013 113 478 A1, DE 10 2009 000 717 A1, EP 2 523 804 B1, DE 10 2005 061 222 A1, and DE 30 05 707 A1. WO 2009 / 124704A1 discloses a floor panel with a wood fiber-based core layer and a thin surface layer, for example, wood veneer. A sublayer comprising wood fibers and a binder is arranged between the core layer and the surface layer. The surface layer, the sublayer, and the core layer are hot-pressed together.

[0004] The invention is based on the objective of demonstrating a plate-shaped building element, in particular a floor panel, which is improved in terms of manufacturing and application technology.

[0005] The solution to this problem demonstrates claim 1.

[0006] The plan is that the plate-shaped component has a plate body made from a mixture of fibrous and / or powdered wood-based material, binders and color pigments, which is pressed together under the influence of temperature and pressure.

[0007] The pressing process takes place between a lower press plate and an upper press plate in a heated press.

[0008] Advantageous embodiments of the basic concept of the invention are the subject of the dependent claims.

[0009] A key aspect of the invention consists in the use of the mixture of fibrous and / or powdered wood material, binders and color pigments.

[0010] This mixture is pressed under the influence of temperature and pressure. The pressed mixture can form the panel body on its own. A core layer can also be integrated into the panel body. This core layer can be a veneer, particularly a real wood veneer. Alternatively, a non-woven fabric or a woven material can be used as a core layer.

[0011] An advantageous embodiment provides a nonwoven fiber layer as the backing. Particularly advantageously, the nonwoven fiber layer consists of cellulose or wood pulp. Specifically, the backing layer is designed as a paper layer or as a sheet-like cellulose fabric or braid. The backing layer can, in particular, be kraft paper. In the case of a nonwoven fiber backing, it consists predominantly of cellulose fibers to which conventional additives such as starch or alum and sizing are added. Furthermore, additives, resins, and other thermoplastic material components can be included in the backing layer.

[0012] It is also possible to combine different flat support layers. The support layer can also be multi-layered.

[0013] The veneer substrates are made of wood. Typically, two veneer layers are arranged on top of each other. Preferably, the veneer layers are oriented perpendicular to each other. The veneer layers have a thickness of 0.3 mm to 0.9 mm. The wood moisture content should preferably be less than 14%.

[0014] In the case of a fiber fleece backing layer, this preferably has a basis weight of 80 g / m² to 500 g / m². It is particularly advantageous if the fiber fleece is impregnated with resins. In this embodiment, the fiber fleece backing layer already contains resins that are melted in during the pressing of the panel body.

[0015] The mixture of fibrous and / or powdered wood-based material, binders, and color pigments is also referred to as a powder mixture within the scope of the invention. The wood fibers contained in the powder mixture have a length of up to 500 µm.

[0016] The proportion of wood-based material in the mixture is at least 30%. In particular, the proportion of wood-based material in the mixture is over 30%.

[0017] The mixture may also contain additives, such as effect particles like mica, and / or anti-abrasive additives, such as corundum.

[0018] An ecologically and economically advantageous aspect is that the wood-based material is a by-product of the production and / or processing of high-density fiberboard (HDF). Fiberboard, particularly high-density or medium-density fiberboard, which is used, for example, in the production of laminate or parquet flooring, is generally profiled along its edges. The resulting by-products in the form of wood flour are used in the invention as by-products for the production of the mixture according to the invention.

[0019] The plate-shaped component may also have reinforcement. In particular, nonwoven fabrics, rovings, or fiberglass fabrics are used as reinforcements, which are integrated into the plate-shaped component or the plate body.

[0020] The reinforcement can contain thermoplastic material components that melt when the floor covering is pressed and advantageously influence or support the formation of the plate-shaped building element and its properties, such as elasticity.

[0021] The surface of a plate-shaped component according to the invention can be machined. In particular, the surface is ground, embossed, brushed and / or sealed. Painting the surface is also possible.

[0022] Furthermore, the surface can be printed with a decoration.

[0023] The plate-shaped component has a thickness between 0.1 mm and 5 mm. With application rates of the mixture ranging from 100 g / m² to 2,000 g / m², the resulting plate thickness ranges from 0.1 mm to 1.5 mm. Depending on the binder and its composition, the plate can be extremely hard and durable or flexible. Elastic properties can also be advantageously incorporated. This is beneficial during installation as well as in use. The plate-shaped components are preferably rectangular. Their practical application is improved by profiling the edges and incorporating locking mechanisms. These locking mechanisms mechanically connect adjacent components within a surface covering, particularly a floor covering. The locking mechanisms are designed, in particular, as a click system.

[0024] To produce a plate-shaped component according to the invention, the mixture of fibrous and / or powdered wood-based material, binders, and color pigments is sprinkled onto a press plate. In particular, a press plate made of a material with good thermal conductivity is used. The press plate is preferably made of metal, ideally a light metal such as aluminum. The press plate, sprinkled with the mixture, is then inserted into a heated press. There, the mixture is compressed, forming the plate-shaped component.

[0025] A key aspect is that the press plate is designed in such a way that water contained in the mixture, or liquid resulting from the reaction of the mixture components during pressing, can escape without damaging the plate body, for example, by causing blistering. For this purpose, the press plate can have pores or be micro-perforated. Furthermore, the press plates can be made of sintered materials, particularly sintered metal, which exhibit porosity and absorb or release moisture.

[0026] Furthermore, a metal pressing plate has the advantage that the plate-shaped component is also heated from below during pressing. This results in more uniform curing of the plate-shaped component.

[0027] The press plate can also be structured or have a structured pressing surface, which gives the plate body a surface texture during pressing. The structuring or profiling of the press plate can also serve to wick away moisture. As explained above, this can neutralize residual moisture or process moisture during pressing.

[0028] The contact between the plate body and the lower pressing plate during the pressing process ensures uniform curing and prevents warping of the plate-shaped component. The pressing plate can also be coated with a release agent, such as an emulsion, which ensures that the plate bodies can be easily removed from the pressing plate after pressing. The use of release papers, silicone edges, or similar materials as release agents is also possible.

[0029] In the production of a plate-shaped component based on a layered body, the mixture is sprinkled onto the substrate layer, as described above. The substrate layer has been previously positioned on the press plate. Subsequently, the structure consisting of the substrate layer and the powder mixture is pressed together in a press under the influence of temperature and pressure.

[0030] It is also possible, in principle, to apply the powder mixture as a layer onto the press plate and then place the carrier layer on top of the powder mixture. During the pressing process, the carrier layer is then embedded in the matrix of the molten powder mixture between the lower and upper press plates.

[0031] Within the scope of the invention, aminoplastic resins or polyurethanes are used as binders, in particular. Aminoplastics are especially advantageous. Melamine resin is a binder that is advantageous in practice. In addition to melamine resins, urea resins, phenolic resins, or mixtures thereof are also possible. Furthermore, polyurethanes or prepolymers are also well suited as binders.

[0032] During the pressing process, the substrate, such as veneers or an embedded fleece, is saturated and impregnated by the molten powder mixture. As a result, a resin layer also forms on the underside of the substrate.

[0033] One aspect of the invention is that the carrier layer is impermeable to the powder mixture in its initial state. Consequently, the powder mixture can be advantageously distributed onto the carrier layer using spreading devices. In this state, the carrier layer is dense. Only during the pressing process, under pressure and temperature, is the powder mixture melted, making the carrier layer permeable. The carrier layer can soften during the pressing process, allowing the melted powder mixture to completely penetrate and / or infiltrate the carrier layer.

[0034] The pressing force is greater than or equal to 35 kg / cm². The pressing temperatures are greater than 120°C and less than 220°C. The pressing times refer to the temperature of the upper pressing plate. That is, the upper pressing plate has a temperature greater than 120°C within the specified temperature range. The pressing times are 10 seconds and 120 seconds, specifically between 15 seconds and 55 seconds.

[0035] The pressing temperature at the lower pressing plate can be lower than the temperature of the upper pressing plate. A temperature difference of up to 100°C between the upper and lower pressing plates is possible and also advantageous. The temperature of the lower pressing plate is 25°C or higher. Preferably, the temperature of the lower pressing plate during the pressing process is greater than 60°C.

[0036] After pressing, the finished products, i.e., the plate-shaped components, are stacked and cooled to room temperature. During this process, the individual plate-shaped components are carefully stacked straight to avoid deformations and unevenness.

[0037] Another advantageous manufacturing process involves pre-curing the powder mixture before pressing it in the press. This creates a skin on the surface of the powder mixture resting on the press plate. Skin formation can occur through the initiation of a reaction by the binders, similar to a gelling process, or through the application of moisture, for example in the form of a water mist, and / or through heat treatment, for example with an infrared lamp. The skin formation fixes the surface, as well as the color and design. Furthermore, it prevents the powder mixture from becoming airborne during the pressing process.

[0038] The plate-shaped component according to the invention can, in principle, be used without a backing plate, for example, a backing plate made of compressed fiber material. This is a use as a direct surface covering. Of course, it is also possible to apply components according to the invention to backing plates or similar backing materials, in particular by gluing them on.

[0039] Since the plate-shaped building elements can also be designed to be elastic, flexible and bendable, it is also possible to use the building elements as cladding for curved or round structures, such as columns and the like.

Claims

1. Plate-shaped building element, in particular a floor panel, having a plate body, the plate body being formed from a mixture of fibrous and / or powdered wood-based material and binder, which is compressed under the influence of temperature and pressure, a support layer being integrated into the plate body, the support layer consisting of at least one wood veneer, characterized in that two veneer support layers are arranged one above the other and the two veneer support layers are aligned transversely to one other.

2. Plate-shaped building element according to any of the preceding claims, wherein the veneer support layers have a thickness of 0.3 mm to 0.9 mm.

3. Plate-shaped building element according to either of the preceding claims, wherein the wood moisture of the veneer support layers is less than 14%.

4. Plate-shaped building element according to any of the preceding claims, wherein a reinforcement, in particular a fiber web or a layer of woven fabric, is incorporated.

5. Plate-shaped building element according to claim 4, wherein the reinforcement contains thermoplastic material components.

6. Plate-shaped building element according to any of the preceding claims, wherein the wood-based material is a by-product of the production and / or processing of compacted fiberboard.

7. Plate-shaped building element according to any of the preceding claims, wherein a surface of the plate-shaped building element is polished, embossed, brushed, sealed and / or painted.

8. Plate-shaped building element according to any of the preceding claims, wherein the plate body has a thickness of between 0.1 mm and 5 mm.

9. Plate-shaped building element according to any of the preceding claims, wherein the plate body has a thickness of between 0.1 mm and 1.5 mm.

10. Plate-shaped building element according to any of the preceding claims, wherein the plate body is profiled at the edges and provided with locking means.