CUSTOMS ELEMENT

Description

[0001] The invention relates to a covering element for a floor, wall and / or ceiling covering. In particular, the present invention relates to a laminate covering element or a covering element for a laminate floor or laminate covering. The covering element has a top layer structure and a backing board.

[0002] It is known in the prior art that so-called damping layers, which can serve as impact sound insulation or are intended for impact sound insulation, are provided for acoustic damping. It is also known in the prior art to arrange such damping layers as a separate component beneath the flooring or to connect them to the underside of the flooring element. For example, the damping layer can directly adjoin the backing of the flooring element. Furthermore, the damping layer can also be used to compensate for unevenness in the substrate. An improved arrangement or adaptation of the flooring element to the substrate can therefore also be achieved via the damping layer.

[0003] In practice, however, it has been found that a damping layer directly bonded to the flooring element, for example, one that is bonded to the backing layer, cannot provide the desired impact sound insulation properties. For this, it is generally essential to lay separate insulation boards on the subfloor. The flooring elements must then be laid on top of these insulation boards.

[0004] Furthermore, a disadvantage is that the laminate flooring elements known in the prior art create a hard feel underfoot and are comparatively stiff or hard to the touch. This ultimately reduces the comfort of a laminate floor. Even with the additional integration of a damping layer, a more flexible feel cannot be achieved in the laminate flooring element.

[0005] The object of the present invention is now to improve a covering element of the type mentioned at the outset with regard to its damping properties and with regard to user comfort.

[0006] The aforementioned problem is solved according to the invention by a covering element for a floor, wall and / or ceiling covering, which is preferably composed of a plurality of covering elements, in particular a laminate covering element, wherein the covering element comprises a top layer structure, a stability layer, a damping layer and a backing board. The stability layer adjoins the top layer structure on its rear side. The stability layer is also made of wood and / or a wood-based material and / or consists of wood and / or a wood-based material. The damping layer adjoins the stability layer on its rear side. The damping layer is designed as an elastic and / or acoustically damping layer. The backing board, in turn, adjoins the damping layer on its rear side.

[0007] In this context, it is understood that further layers may be arranged between the aforementioned layers, but this is not mandatory. In any case, the resulting sequence, starting from the upper layer structure, follows this structure: upper layer structure - stability layer - damping layer - support plate

[0008] Therefore, the aforementioned use of the term "rear" is to be understood as meaning that the upper layer structure corresponds to the top of the covering element and the carrier plate to the underside of the covering element.

[0009] In contrast to the prior art, according to the invention the damping layer is not arranged below, but above the carrier plate and below a stability layer.

[0010] In developing the invention, it was discovered that by arranging the damping layer above the carrier board, the acoustic and / or elastic damping properties can be provided very effectively, while simultaneously achieving noticeable comfort or a compliant behavior under load on the flooring element, without impairing the other, particularly mechanical, requirements of the flooring element. The present inventive concept is particularly advantageous when used for a laminate flooring element, especially since resin-impregnated paper can preferably only be laminated onto HDF / MDF, which results in a limitation in the prior art. According to the invention, the production of the flooring element can now be integrated into a lamination process to form a laminate.

[0011] However, if only the damping layer were placed above the carrier plate, excessive indentation under load would occur. Furthermore, the damping layer would be relatively easily damaged, and a permanent relief pattern would develop after only a short period of use due to the stress on the surface element.

[0012] These disadvantages can be avoided by using the stability layer according to the invention. The invention therefore relies heavily on the stability layer and the damping layer. According to the invention, it has been found that by arranging the stability layer above the damping layer, the damping properties and also the comfort of the surface element can be improved, while at the same time the damping layer can be protected, in particular from mechanical stresses. Furthermore, the stability layer can also prevent disruptive relief contours that would otherwise arise from stress on the damping layer. The stability layer thus ensures that the predetermined and desired structure is present on the outer surface of the surface element, which is preferably not altered, or if so, only slightly or minimally, by mechanical stress on the surface element.At the same time, the damping layer also causes or ensures a certain yielding behavior of the covering element.

[0013] Furthermore, it has been found according to the invention that the stability properties required to compensate for the damping layer can be optimally achieved by constructing the stability layer from wood and / or a wood-based material. Under stress, the stability layer allows for load distribution, which in turn leads to lower point loads on the damping layer. Thus, a guaranteed load distribution for the damping layer results in a large-area load that can be balanced accordingly without the presence of point load peaks. The comfort perceived by the user is thereby further ensured, or indeed, is only ensured according to the invention, by the damping layer.

[0014] The design of the stabilizing layer made of wood and / or a wood-based material is to be understood in particular as meaning that the material of the stabilizing layer consists of wood or comprises a large proportion of wood (i.e., more than 50% by weight). If the stabilizing layer is made of a wood-based material, this refers in particular to a design of the stabilizing layer as a hardboard, such as medium-density fiberboard (MDF), high-density fiberboard (HDF), medium-density fiberboard (FHM), and hard fiberboard (HFH). Such fiberboards are known in the prior art.

[0015] Wood fiberboards consist primarily of wood. The stabilizing layer can contain at least 70% by weight of wood, preferably at least 75% by weight, and more preferably at least 80% by weight. In addition to wood, the stabilizing layer can also contain additional material that serves to reinforce and / or bind the wood layer together. For example, the stabilizing layer can also contain water, particularly from the moisture content of the wood, and / or adhesive and / or resin. The water content can be between 1% and 10% by weight, preferably between 4% and 6% by weight. The adhesive and / or resin content can be up to 15% by weight, particularly up to 10% by weight. Further additives, such as wax emulsion, can also be provided, but these can then constitute less than 1% by weight of the material in the stabilizing layer.

[0016] The material of the stabilizing layer results in a bulk density of between 600 and 1200 kg / m³, preferably between 600 and 1000 kg / m³. The stabilizing layer is therefore particularly preferably designed as a wood fiberboard or as a layer of wood.

[0017] As previously explained, a wood fiberboard can contain highly fragmented wood. Different types of wood fiberboard can vary in their hardness and / or material density. Fiberboard is not the same as particleboard, even though these products are byproducts of the sawmill industry. However, particleboard contains wood chips with a significantly greater thickness than wood fiberboard, which contains very small wood fiber particles.

[0018] A wood fiberboard can be produced in particular by pressing the material.

[0019] In a particularly preferred embodiment, the flooring element is polyvinyl chloride-free (PVC-free). A PVC-free flooring element offers the advantage of achieving a particularly beneficial floor, especially from an ecological perspective. PVC floors or flooring elements containing PVC are primarily resilient floor coverings. In the prior art, it is common practice to add plasticizers to PVC floors. However, plasticizers are not entirely harmless to health, which is why health concerns arise in practice regarding PVC floors. It is therefore advantageous to provide a plasticizer-free or PVC-free floor using plasticizer-free or PVC-free flooring elements.

[0020] The present invention does not, however, preclude the possibility that in further alternative embodiments the covering element contains at least some polyvinyl chloride or small amounts (< 5 wt%). In particular, the upper layer structure may contain or consist of PVC. A key aspect of the invention is that the stabilizing layer is made of wood and / or a wood-based material. This can also be combined with a PVC-containing upper layer structure, while simultaneously ensuring the aforementioned particularly advantageous properties of the covering element.

[0021] It is particularly preferred that the stabilizing layer is plastic-free or at least substantially plastic-free. A plastic-free design does not preclude the stabilizing layer from containing adhesive and / or resin, especially if this is not made of plastic. A stabilizing layer that is at least substantially plastic-free is preferably understood to mean that the stabilizing layer has a plastic content in the material of less than 5 wt.%, preferably less than 3 wt.%, and more preferably less than 1 wt.%.

[0022] It is particularly preferred that the carrier plate and / or the covering element has connection geometries on its edges, in particular tongue-and-groove connection geometries of a click connection, for connecting adjacent covering elements, preferably to form a covering. The carrier plate can have complementary connection geometries on opposite edges. For example, the longitudinal sides of the carrier plate and / or the covering element can have complementary connection geometries, and the end faces, which can also be referred to as head faces, can also have complementary connection geometries. For example, a groove can be provided on one edge face, which is designed to interact with the tongue on the opposite edge face, which is complementary to the groove, thus preferably ensuring a click connection.

[0023] In a further preferred embodiment of the invention, the stabilizing layer has a thickness of between 0.3 and 5 mm, preferably between 0.5 and 2 mm. Tests conducted during the development of the invention have shown that the stability properties of a stabilizing layer made of wood or a wood-based material can be reliably ensured at the aforementioned thicknesses.

[0024] Preferably, the damping layer has a thickness of between 0.3 and 5 mm, more preferably between 0.5 and 2 mm. The thicknesses of the damping layer and the stabilizing layer can be the same or different. The thicknesses of the stabilizing layer and the damping layer are to be selected according to the desired damping and stabilizing properties, as well as the desired perceived comfort for the user.

[0025] The thickness of the backing plate can be selected depending on the application of the covering element. It is particularly preferred if the backing plate has a thickness between 2 mm and 15 mm, preferably between 4 mm and 10 mm, and more preferably between 6 mm and 9 mm.

[0026] Furthermore, the upper layer structure can include a decorative layer and / or a top-side wear layer. The decorative layer can be, in particular, a decorative film and / or decorative paper and / or a decorative print and / or a decorative lacquer layer. The top-side wear layer can be designed as an overlay, in particular a corundum-containing overlay, and / or as a protective lacquer and / or protective oil and / or as a protective film.

[0027] The overlay material is preferably polyurethane (PUR) and / or made of it. In particular, the wear layer is designed as a PUR-based protective overlay film. PUR provides high sound attenuation. Therefore, this material choice allows the wear layer to also provide a damping effect in addition to the damping layer.

[0028] The protective film can be made of polypropylene (PP), polyethylene (PE), and / or polyurethane (PUR). As previously explained, the upper layer structure can also contain PVC. The upper wear layer can be a surface layer, preferably resin-coated. In particular, the upper wear layer can contain corundum particles, thus enabling it to function as a wear layer. Corundum is particularly suitable due to its high hardness. This allows the corundum particles to provide increased protection for the decorative paper, which is preferably resin-coated and / or (through-)impregnated.

[0029] Preferably, the upper layer structure can also include a wood veneer and / or a wood surface layer. However, the wood veneer and / or wood surface layer can also be covered and / or sealed and / or protected by a top-side wear layer.

[0030] In further embodiments, it can also be provided that the stability layer is designed as a wood veneer and / or wood top layer and the upper layer structure is a sealing layer and / or a wear layer provided on the upper side of the stability layer, in particular in which the upper layer structure no longer needs to have a decorative foil or decorative layer.

[0031] In a further preferred embodiment, the stabilizing layer, as previously explained, is formed as a hardboard, in particular MDF (medium-density fiberboard) and / or HDF (high-density fiberboard) and / or HFM / MB (medium-hard fiberboard) and / or HFH / HB (hardboard), and / or as a wood layer, in particular made of poplar or linden. Materials of the aforementioned type ensure, in particular, the stability properties according to the invention.

[0032] Alternatively or additionally, the stabilizing layer can be designed as a molded fiberboard, in particular a molded natural fiberboard. Natural fibers, especially natural materials and / or recycled fibers, can be used. Particularly preferably, the stabilizing layer designed as a molded fiberboard comprises and / or consists of recycled materials, especially cellulose fibers and / or agricultural waste. Molded fiberboards of the aforementioned type are particularly suitable as a replacement for MDF and / or HDF boards. Preferably, biodegradable molded fiberboards are used, which are therefore particularly advantageous from an ecological perspective. Molded natural fiberboards for the stabilizing layer can comprise fibers and / or components selected from the group of old newspapers, cardboard, and agricultural by-products, in particular straw, bagasse, and / or animal excrement.Molded fiberboards formed in this way are preferably free of pollutants, highly resilient and have a low weight when used as a stabilizing layer according to the invention.

[0033] In a particularly preferred embodiment, the damping layer comprises or consists of cork. In this embodiment, the damping layer preferably has a density between 150 and 550 kg / m³, more preferably between 200 and 300 kg / m³. Furthermore, the damping layer can comprise a cork composite material, in particular containing cork and polypropylene, polyethylene, polyurethane, and / or an elastic plastic.

[0034] Alternatively or additionally, in further preferred embodiments, the damping layer may also be made of a foam material, preferably a plastic foam material, and / or consist thereof. The foam density of the damping layer can then depend on the type of plastic selected and the material thickness. In particular, the density of the damping layer as a foam layer can be between 100 and 200 kg / m³, especially for a polyethylene-containing foam material, and / or between 250 and 450 kg / m³, especially for a polyurethane (PUR)-containing material, wherein the damping layer for the aforementioned densities can have a material thickness of between 0.5 and 2 mm. It is also possible, in principle, for the plastic and / or foam material of the damping layer to be cross-linked.

[0035] Furthermore, according to the invention, the damping layer can have a modulus of elasticity of at most 5 MPa, preferably between 0.2 and 5 MPa, and more preferably between 2 and 4 MPa. The modulus of elasticity was measured, in particular, in a tensile test. The modulus of elasticity is a material property that, in the case of linear-elastic behavior, describes the proportional relationship between stress and strain during the deformation of a solid body.

[0036] Advantageously, a counter-tension is provided on the underside of the carrier plate. This counter-tension can, in particular, ensure that undesirable deformation of the covering element is avoided. Ultimately, the counter-tension can compensate for forces acting on the carrier plate. Thus, the counter-tension balances stresses in the covering element. In the prior art, a counter-tension typically consists of a veneer, paper (especially kraft paper), and / or a foil.

[0037] Preferably, the support plate is designed as a panel body, in particular as a wooden panel body, and / or as an HDF and / or MDF panel and / or as a panel body made of or consisting of plastic. In further embodiments, it may therefore also be provided that the support plate has a plastic material and / or consists of plastic.

[0038] Furthermore, in a further preferred embodiment of the invention, at least two layers of the covering element and / or the damping layer, the carrier board, the stabilizing layer, and / or the top layer structure may be pressed together, preferably to form a laminate. In particular, at least one layer, preferably at least one layer of the top layer structure, preferably the decorative paper, and / or the backing layer, may be resin-impregnated. A melamine resin is particularly preferred. It is especially preferred if the resin-impregnated layer is at least substantially completely resin-impregnated and / or fully impregnated.

[0039] In particular, melamine resin can also contain other fillers, especially polyurethane (PUR).

[0040] Alternatively or additionally, it can be provided that at least two layers, preferably all layers, of the covering element have been bonded together, in particular wherein the carrier plate, the stability layer and the damping layer are bonded together.

[0041] In a particularly preferred embodiment, at least two layers of the covering element are pressed together and at least two further layers are bonded together. It is particularly advantageous if the carrier board, the stability layer, and the damping layer are bonded together, and this pre-product thus formed is then pressed together with the, in particular resin-impregnated, upper layer structure and the, in particular resin-impregnated, backing layer. Alternatively, it can also be provided that the backing layer and / or the upper layer structure is / are laminated with the bonded pre-product. It is particularly preferred that the backing layer is impregnated with melamine resin before the pressing process. Alternatively or additionally, it is preferable that the upper layer structure, in particular the decorative layer, preferably the decorative paper, and / or the overlay, is / are impregnated with melamine resin before the pressing process.

[0042] The aforementioned process steps, which will be discussed later in connection with the process according to the invention, are also to be considered tangible features, since they are evident in the final product.

[0043] Furthermore, the aforementioned problem is solved by a method for manufacturing a covering element according to one of the aforementioned embodiments. According to the invention, the method comprises the following process steps: A) Provision of a carrier plate and a stabilizing layer; B) Connection of the carrier plate to a damping layer, preferably by extruding the damping layer at least indirectly onto the carrier plate and / or preferably by pressing and / or laminating the carrier plate and the damping layer together; C) Connection of the damping layer to the stabilizing layer, preferably by pressing and / or laminating; D) Connection of the stabilizing layer to an upper layer structure, preferably by pressing and / or laminating.

[0044] It is understood that, with regard to advantages and preferred embodiments of the method according to the invention, reference may be made to the advantages and embodiments of the covering element discussed above, which may also apply to the method according to the invention without requiring further explicit mention. Likewise, it is understood according to the invention that the following descriptions of the method according to the invention may also apply to the covering element according to the invention without requiring further explicit mention.

[0045] In a preferred embodiment of the method, process steps B) and C) and / or C) and D) can be carried out simultaneously. In particular, the layers of the covering element can be pressed and / or bonded and / or laminated together at least simultaneously. A combination of bonding and pressing the layers can also be provided, for example, by bonding some layers together and pressing them together to form further layers.

[0046] For the compression of the layers, it is advantageous if at least one layer of the coating element is resin-impregnated. For the purposes of the present invention, resin-impregnation also includes a layer that is at least partially or fully impregnated.

[0047] According to the invention, it can also be provided that a bonding layer made of resin, preferably a melamine resin, is provided between the two layers for pressing them together.

[0048] Regardless of whether the resin application is provided by the resin application to a layer of the paving element or by an additional bonding layer integrated into the paving element, a injection process, preferably in a short-cycle (CT) injection molding machine, ensures that a permanent and secure bond between the layers can be guaranteed.

[0049] If a bonding layer is used to connect two adjacent layers during grouting, it is applied to at least one layer on the side facing the other layer before grouting.

[0050] The resin used for pressing, which is provided in at least one layer, is in particular at least one aminoplastic, thermoplastic, or thermosetting resin or reactive resin, especially melamine resin. The resin is preferably characterized in that it first liquefies and then hardens or reacts under the influence of temperature and pressure. During activation of the resin, preferably of the decorative layer and / or the backing layer, the resin penetrates in particular into the pores of the adjacent layers, so that penetration into both layers occurs and a strong bond to the adjacent layer results.

[0051] Furthermore, it may be possible to use bonding layers made of a resin material in addition to the aforementioned layers of the paving element. These bonding layers can then be arranged between the layers to be pressed together. A resin of the aforementioned type can be provided in the bonding layer, which, during pressing, is introduced into the adjacent layers and bonds them together in a material-bonded manner.

[0052] The temperature during pressing depends primarily on the resin material used. Pressing is preferably carried out at a temperature above 80 °C. The pressing temperature refers to the temperature at the press plate of the press. It is therefore present on both the top and bottom surfaces of the coating element.

[0053] Higher temperatures are required for thermosetting or reactive resins, so injection molding typically takes place at temperatures between 180 °C and 210 °C. For resins in the form of urea-formaldehyde condensation products, the injection molding temperature is lower compared to reactive resins, generally between 100 °C and 140 °C. Urea-formaldehyde condensation products belong to the group of urea resins and thus also to the aminoplastic resins.

[0054] Furthermore, a sufficiently high pressing pressure must be present in the press to cure the resin layer. A short-cycle press (KT press) is particularly suitable. The pressing pressure is preferably greater than or equal to 1000 kPa or 100 N / cm², preferably greater than 3500 kPa or 350 N / cm².

[0055] Preferably, the upper layer structure can be prepared before being joined to the stabilizing layer or produced during the joining process. Furthermore, the upper layer structure can be single-layered or multi-layered. In the case of a multi-layered upper layer structure, it is advantageous if it comprises at least one resin-coated layer or a resin-based bonding layer, particularly if the upper layer structure is intended for subsequent injection grouting.

[0056] In a particularly preferred embodiment of the method according to the invention, the carrier plate, the damping layer, and the stabilizing layer are first bonded together and then pressed together with the upper layer structure, which is preferably at least partially resin-coated or impregnated, and optionally with the counter-layer, which is preferably resin-coated and / or fully impregnated. Alternatively, the carrier plate, the damping layer, and the stabilizing layer can first be bonded together, and then the upper layer structure and optionally the counter-layer are laminated.

[0057] In another preferred alternative, it can be provided that first the upper layer structure, in particular the resin-coated one, is pressed together with the stability layer and optionally the counter-layer, preferably resin-coated, with the carrier plate - each separately - and then the damping layer is laminated together with the stability layer and the carrier plate.

[0058] The aforementioned process configurations represent different possibilities for forming a surface element. In this context, the respective process can be adapted according to the materials of the surface element.

[0059] In the aforementioned process configurations for manufacturing the covering element, a so-called pre-product is used. According to the aforementioned embodiments of the inventive method, a pre-product is achieved by bonding the damping layer, the stability layer, and the carrier plate. Providing a pre-product offers the advantage of simplified manufacturing and ultimately reduced storage costs, since the pre-product can be bonded with different top layer structures, which, for example, may have different decorative finishes.

[0060] In addition to the aforementioned precursor, other preferred precursors can also be provided. Furthermore, more than one precursor can be provided in the inventive process for manufacturing the coating element.

[0061] Particularly preferably, the intermediate product can be stored. In a further preferred embodiment, the intermediate product can be formed by bonding the damping layer, the stabilizing layer, and the upper layer structure, or by bonding the carrier plate to the damping layer, or by bonding the stabilizing layer to the upper layer structure, or by bonding the carrier plate, the damping layer, and the stabilizing layer. Bonding of the aforementioned layers can preferably be achieved either by bonding and / or laminating and / or by a pressing process.

[0062] Preferably, the upper layer structure can be laminated and / or bonded and / or printed and / or lacquered onto a pre-product formed by combining the carrier board, the damping layer, and the stability layer. Bonding the upper layer structure to the aforementioned pre-product is particularly preferred for carrier boards made of a plastic such as polyethylene, polypropylene, and / or PVC, and / or for use in a parquet flooring element.

[0063] In a further embodiment of the method according to the invention, two precursors are provided for the formation of the covering element. One precursor can be provided by combining the upper layer structure with the stability and damping layer, while a further precursor can be formed by the carrier plate and the counter-layer. Both precursors can then be bonded together.

[0064] Furthermore, according to another preferred embodiment, it is provided that after the layers of the covering element are joined, the edge connection geometries are incorporated into the covering element, in particular into the carrier plate. Alternatively, it can also be provided that the connection geometries are already provided in the carrier plate before being joined with the other layers to form the covering element.

[0065] Furthermore, it is expressly pointed out that all the aforementioned and subsequent intervals include all intermediate intervals and individual values ​​contained therein, and that these intermediate intervals and individual values ​​are to be regarded as essential to the invention, even if these intermediate intervals or individual values ​​are not specifically specified in detail.

[0066] It shows: Fig. 1 shows a schematic layer structure of a coating element according to the invention, Fig. 2 shows a schematic layer structure of a further embodiment of a coating element according to the invention, Fig. 3 shows a schematic layer structure of a further embodiment of a coating element according to the invention, Fig. 4 shows a schematic perspective view of a coating element according to the invention, Fig. 5 shows a schematic perspective view of a coating according to the invention, Fig. 6 shows a schematic view of a method according to the invention, Fig. 7 shows a schematic view of a method step according to the invention for forming a precursor according to the invention, Fig. 8 shows a schematic view of a further embodiment of a method according to the invention, Fig. 9 shows a schematic view of a further embodiment of a method according to the invention, and Fig. 10 shows a schematic view of a further embodiment of a method according to the invention.

[0067] Fig. 1 Figure 1 shows the layer structure of a covering element 1. The covering element 1 is intended for use in forming a floor, wall, and / or ceiling covering 2. Several covering elements 1 can be joined together to form a covering 2. A covering 2 is shown schematically in the Fig. 5 As shown. In particular, a laminate flooring element is provided as flooring element 1.

[0068] Fig. 1 This shows that the covering element 1 has an upper layer structure 3. The upper layer structure 3 can be single-layered or multi-layered. A stability layer 4 adjoins the upper layer structure 3 on the back. The stability layer 4 is made of wood and / or a wood-based material. Fig. 1 As shown, a damping layer 5 adjoins the stability layer 4 on the rear side. The damping layer 5 is an elastic and / or acoustically damping layer. A support plate 6 adjoins the damping layer 5 on the rear side. The support plate 6 can be designed as a plate body. In the Fig. 1 In the illustrated embodiment, a counterweight 15 is also provided, which can optionally be provided on the rear side of the carrier plate 6.

[0069] A multi-layered formation of the upper layer structure 3 is used, among other things, in the Fig. 2 shown.

[0070] The stability layer 4 consists largely of wood, wood particles and / or wood fibers. In particular, the proportion of wood material, which can be provided as continuous wood, wood particles and / or wood fibers, in the stability layer 4 is at least 65 wt.%, preferably at least 70 wt.%, and particularly at least 80 wt.%.

[0071] The damping layer 5 ensures the cushioning properties for the flooring element 1. This damping layer ultimately provides a high level of comfort on the top surface of the flooring element 1, which is the usable surface. The stability layer 4, on the other hand, ensures load equalization / distribution when the flooring element 1 is subjected to stress, particularly when mechanical loads act upon it, such as when walking on the flooring 2. This load distribution ensures a long service life for the flooring element 1, while simultaneously utilizing the cushioning properties of the damping layer 5 to its advantage. The stability layer 4 also protects the damping layer 5 from further external influences, thus guaranteeing the functionality of the damping layer 5 over a long period of use.

[0072] Furthermore, integrating the damping layer 5 into the layer structure of the flooring element 1 offers the advantage that a separate damping layer 5 beneath the flooring 2 is no longer necessary, which can significantly reduce the installation effort for a damping floor covering 2. The flooring element 1 shown in the embodiments can be installed in a manner familiar to the user, without requiring any further special modifications during installation. This also reduces installation errors.

[0073] The in Fig. 1 The depicted covering element 1 is PVC-free. The in Fig. 3 However, the depicted covering element 1 also has PVC as its material.

[0074] Furthermore, the in Fig. 1 The depicted stability layer 4 is designed to be plastic-free or at least substantially plastic-free. A plastic-free design of the stability layer 4 does not preclude it from containing a resin or adhesive, particularly for bonding the wood fiber components. Preferably, the plastic content in the stability layer material is less than 5 wt.%, more preferably less than 1 wt.%, which is what is meant by a plastic-free design of the stability layer 4.

[0075] In Fig. 4 The figure shows that the carrier plate 6 and the covering element 1 have connection geometries 7 on their longitudinal sides. It is not shown in detail that these connection geometries 7 can also be provided on the end faces. In particular, tongue-and-groove connection geometries of a click connection for connecting adjacent covering elements 1 are provided as connection geometries 7. Preferably, the connection geometries 7 are formed complementarily to each other on opposite edge faces 8 of the carrier plate 6 and the covering element 1, respectively. Thus, one long side can have a groove and the opposite long side a tongue formed complementarily to the groove for forming the click connection. Ultimately, adjacent covering elements 1 can be connected to each other via the connection geometries 7 to form a covering 2, as shown schematically in the figure. Fig. 5 is shown.

[0076] In the Fig. 2 The different thicknesses of the individual layers of the paving element 1 are shown. The in Fig. 2 The depicted stability layer 4 can have a thickness 9 between 0.3 and 5 mm, in particular between 0.5 and 2 mm. The damping layer 5, in turn, can have a thickness 10 between 0.3 and 5 mm, in particular between 0.5 and 2 mm. The thicknesses 9 and 10 of the stability layer 4 and the damping layer 5 can be at least substantially the same or different from each other.

[0077] Furthermore, the carrier plate 6 can have a thickness 11 of between 2 and 15 mm, preferably between 4 and 10 mm. The thickness 11 of the carrier plate 6 is selected depending on the desired installation height or overall height of the covering element 1.

[0078] In Fig. 2 The figure shows that the upper layer structure 3 comprises a decorative layer 12 and a top-side wear layer 13. It is not shown that the upper layer structure 3 comprises only a decorative layer 12 or only a top-side wear layer 13. The decorative layer 12 can be a decorative film, a decorative paper, a decorative print, and / or a decorative lacquer layer. The top-side wear layer 13, in turn, can be a protective film, an overlay, a protective lacquer, and / or a protective oil. The overlay, in particular, contains corundum particles or is corundum-based. This ultimately increases its resistance to wear.

[0079] It is not specified in detail that the overlay is made of polyurethane (PUR) and / or consists of polyurethane. In particular, the upper wear layer 13 is designed as both an overlay and a protective film, and is made of polyurethane and / or consists of polyurethane. This design of the wear layer 13 ensures sound-absorbing properties.

[0080] The upper layer structure 3 can comprise a wood veneer and / or a wood top layer 14. In Fig. 3 The figure shows that the stability layer 4 is designed as a wood veneer and / or wood surface layer 14. In this case, the stability layer 4 can also be considered part of the upper layer structure 3. An upper layer structure 3 or a top-side wear layer 13, in particular a coating, can then be applied to the wood veneer and / or wood surface layer 14 to protect the wood.

[0081] The in Fig. 2 The depicted stability layer 4 is designed as a hardboard. Various hardboards are suitable in this context, in particular MDF and / or HDF boards and / or HFM / MB and / or HFH / HB boards. Alternatively, the stability layer 4 can also be designed as a wood layer, in particular made of poplar or linden. In this configuration, it is particularly preferred if the stability layer 4 is designed as a wood veneer and / or wood face layer 14, as previously explained, and in particular consists of poplar or linden.

[0082] Not shown is that the stabilizing layer 4 is designed as a molded fiberboard, in particular a molded natural fiberboard. Specifically, the molded fiberboard can comprise and / or consist of waste cellulose. Alternatively or additionally, the stabilizing layer 4 designed as a molded fiberboard can comprise and / or consist of recycled materials, in particular cellulose fibers and / or agricultural waste. In particular, the stabilizing layer is designed as a flexible, high-density, and compressed molded fiberboard made of waste cellulose, which is preferably biodegradable.

[0083] The in Fig. 1 The damping layer 5 shown comprises cork and / or a cork composite, in particular comprising cork and polypropylene (PP), polyethylene (PE) and / or polyurethane (PUR) and / or other elastic plastics. In further embodiments, the damping layer 5 may comprise and / or consist of a foam material, in particular a plastic foam material. The foam material may also be cross-linked.

[0084] Furthermore, the damping layer can have a modulus of elasticity of at most 5 MPa and, in particular, between 2 and 4 MPa.

[0085] As explained previously, in Fig. 1 The figure shows that a counterweight 15 is arranged on the underside of the support plate 6, which ultimately leads to load distribution. Kraft paper can be used as the counterweight 15. The counterweight 15 can be single-layered or multi-layered.

[0086] The support plate 6 shown in the embodiments is designed as a panel body and can in particular be provided as a hardboard, preferably as an HDF and / or MDF board. In further embodiments not shown in detail, the support plate 6 can also be made of or consist of a plastic material.

[0087] The layers of the covering element 1 can be connected to each other in different ways, which is also recognizable in the final product itself.

[0088] At least two layers of the covering element 1 and / or the damping layer 5, the carrier plate 6, the stability layer 4 and / or the upper layer structure 3 can be pressed together. When pressing, it is particularly preferred if at least one layer is resin-coated, especially at least one layer of the upper layer structure 3 or of the counter-layer 15.

[0089] In Fig. 10 For example, it is shown that the upper layer structure 3 has been pressed together with the stability layer 4 and the carrier plate 6 with the counter-layer 15, whereby in this context the counter-layer 15 and the decorative layer 12 are resin-coated and / or impregnated.

[0090] Alternatively, during the pressing process, a resin bonding layer can be placed between the layers to be pressed. This layer penetrates the adjacent layers during pressing and bonds them firmly together. Melamine resin is the preferred resin.

[0091] Alternatively or additionally, it can also be provided that preferably two layers, in particular all layers, of the covering element 1 are bonded together. In particular, the carrier plate 6, the stability layer 4 and the damping layer 5 can be bonded together, as is the case, for example, in Fig. 9 This is illustrated. Bonding the layers can also be combined with pressing other layers, as will be explained in the context of the process.

[0092] In Fig. 6 Figure 1 shows a schematic sequence of a process for manufacturing a covering element 1 according to one of the previously described embodiments. The process comprises steps A) to D). In step A), the carrier plate 6 and the stability layer 4 are first provided.

[0093] In process step B), the carrier plate 6 is then joined to a damping layer 5. This joining can be achieved, for example, by extruding the damping layer 5 onto the carrier plate 6, particularly if the damping layer 5 is made of or consists of foam. Alternatively, the carrier plate 6 and the damping layer 5 can be pressed and / or laminated together, whereby this joining process can also create a connection to other layers of the covering element 1.

[0094] In the Fig. 6 The depicted process is designed so that process step C) is carried out simultaneously with process step B). However, in other embodiments, which are not shown in detail, it is also possible for the process to be carried out independently of time. In step C), the damping layer 5 is joined to the stability layer 4, preferably by pressing and / or laminating. For example, the damping layer 5, the stability layer 4, and the carrier plate 6 can be joined to each other simultaneously, in particular by bonding.

[0095] In process step D), which is in the Fig. 6 In the illustrated embodiment, if the stabilization layer 4 is carried out after process steps B) and C), the stability layer 4 can be connected to the upper layer structure 3, preferably by pressing and / or laminating.

[0096] As explained previously, process steps B) and C) can be carried out simultaneously. It is not shown in detail whether process steps C) and D) can also be carried out simultaneously, either alternatively or additionally. It is also not shown in detail whether the layers of the covering element 1 are pressed and / or bonded together at least essentially simultaneously. In the Fig. 8 bis 10 In the illustrated embodiments of the method, it is provided that different pre-products 16 are provided for the formation of the coating element 1, which can be produced by joining individual layers of the coating element 1, wherein these pre-products 16 can then be joined to form further pre-products 16 or layers of the coating element 1.

[0097] The upper layer structure 3 may have been provided before being joined to the stability layer 4 or may be produced during the joining process. If the upper layer structure 3 is composed of multiple parts, the upper layer structure 3 as such may be produced, particularly during the joining to the stability layer 4.

[0098] A pre-product 16 can be provided by joining different layers of the covering element 1. Such a pre-product 16 can, in particular, be temporarily stored before being joined to other layers of the covering element 1. Fig. 7 It is shown that a pre-product 16 can be produced by connecting, in particular bonding, the stability layer 4, the damping layer 5 and the carrier plate 6.

[0099] In Fig. 10 Two intermediate products 16 are shown. One intermediate product 16 can be produced by connecting the upper layer structure 3 with the stability layer 4 and another intermediate product 16 by connecting the carrier plate 6 with the counter-layer 15, in particular by pressing.

[0100] It is not shown in detail that a pre-product 16 can also be provided by connecting the damping layer 5, the stability layer 4 and the upper layer structure 3 or by connecting the carrier plate 6 with the damping layer 5.

[0101] The provision of a semi-finished product 16 may depend in particular on the respective storage capacity or the manufacturing process.

[0102] Furthermore, the connection geometries 7 can be incorporated into the edge of the carrier plate 6 and / or into the carrier plate 1 after the covering element 1 has been connected. Alternatively, it can also be provided that the carrier plate 6 already has the connection geometries 7 at its edge before being connected to other layers.

[0103] In the Fig. 8 bis 10 Different schematic representations of each procedure are shown.

[0104] Fig. 8 This shows that a pre-product 16 can first be produced by joining the stability layer 4, the damping layer 5, and the carrier plate 6. These layers can be joined together, in particular, by adhesive bonding. Subsequently, the pre-product 16 is pressed together with the upper layer structure 3 and optionally with the counter-layer 15, particularly in a KT press. In this context, it is particularly preferred if the counter-layer 15 and / or at least one layer, preferably the decorative layer 12, of the upper layer structure 3 is at least partially, preferably completely, resin-coated and / or impregnated, particularly preferably resin-coated, impregnated, and / or saturated with melamine resin.

[0105] A melamine resin is specifically intended as the resin.

[0106] If the layers are not resin-coated, a bonding layer (not shown in detail) is preferably arranged between the layers to be pressed together. This bonding layer can then consist of resin, in particular melamine resin, and penetrate the adjacent layers during pressing.

[0107] In Fig. 8 The figure shows that the upper layer structure 3 is formed during pressing and consists of the upper wear layer 13 and the decorative layer 12.

[0108] In Fig. 9 The illustration shows that the pre-product 16 is first formed by joining, in particular bonding, the stability layer 4, the damping layer 5, and the carrier plate 6. Subsequently, the upper layer structure 3, which can be single- or multi-layered, and optionally the counter-layer 15, are laminated to this pre-product 16. In the case of lamination, a laminating agent is provided that ultimately ensures a material-bonded connection. In this embodiment, the carrier plate 6 can be made of plastic, but this is not required.

[0109] In Fig. 10 A further alternative process configuration is provided, in which two precursor products 16 are initially formed, wherein one precursor product 16 can be assembled into the stability layer 4 by a pressing process of the upper layer structure 3, the upper layer structure 3 being formed in particular by a decorative layer 12 and a top-side wear layer 13. The other precursor product 16 can be formed by joining, in particular pressing, the carrier plate 6 to the counter-layer 15.

[0110] As previously discussed, it is particularly advantageous during the injection molding process if at least one layer is resin-coated or impregnated, or if a resin-based bonding layer is provided between the layers to be injected. Subsequently, the pre-products 16 are joined to form the damping layer 5, preferably by bonding and / or by lamination.

[0111] It is not shown in detail that the damping layer 5 can also be formed on the carrier plate 6 during extrusion and subsequently bonded, laminated and / or pressed to form further layers. Bezugszeichenliste:

[0112] 1. Covering element 2. Covering 3. Top layer structure 4. Stability layer 5. Damping layer 6. Carrier board 7. Connection geometries 8. Edge of 1 9. Thickness of 4 10. Thickness of 5 11. Thickness of 6 12. Decorative layer 13. Top wear layer 14. Wood surface layer / wood veneer layer 15. Backing layer 16. Pre-product

Claims

1. Covering element (1) for a floor, wall and / or ceiling covering (2), in particular laminate covering element, having an upper layer structure (3), a stability layer (4) of wood and / or of a wood-based material adjoining the rear side of the upper layer structure (3), an elastic and / or acoustically damping damping layer (5) adjoining the rear side of the stability layer (4), and a carrier plate (6) adjoining the rear side of the damping layer (5), wherein the covering element (1) is designed to be PVC-free characterized in that the stability layer (4) is at least essentially free of plastic, with a plastic content of less than 3% by weight, preferably less than 1% by weight, of the material.

2. Covering element according to claim 1, characterized in that the stability layer (4) is designed to be free of plastic.

3. Covering element according to one of the preceding claims, characterized in that the carrier plate (6) has connecting geometries (7) on the edge sides for connecting adjacent covering elements (1).

4. Covering element according to one of the preceding claims, characterized in that the stability layer (4) has a thickness (9) between 0.3 to 5 mm, preferably between 0.5 to 2 mm.

5. Covering element according to one of the preceding claims, characterized in that the upper layer structure (3) comprises a decorative layer (12) and / or an upper wear layer (13).

6. Covering element according to one of the preceding claims, characterized in that the upper layer structure (3) comprises a wood veneer layer.

7. Covering element according to one of the preceding claims, characterized in that the stability layer (4) is formed as a hard fiberboard and / or as a wood layer and / or that the stability layer (4) is preferably formed as a shaped fibreboard.

8. Covering element according to one of the preceding claims, characterized in that the damping layer (5) comprises as material cork and / or a cork composite, and / or a foam material and / or consists thereof and / or in that the damping layer (5) has a modulus of elasticity of at most 5 MPa, preferably between 0.2 and 5 MPa, more preferably between 2 and 4 MPa.

9. Covering element according to one of the preceding claims, characterized in that a countermove (15) is provided and / or arranged on the underside of the carrier plate (6).

10. Method for producing a covering element (1) according to any one of the preceding claims, the method comprising the following method steps: A) Providing a carrier plate (6) and a stability layer (4); B) Bonding the carrier plate (6) to a damping layer (5), preferably by extruding the damping layer (5) at least indirectly onto the carrier plate (6) and / or preferably by pressing and / or laminating the carrier plate (6) and the damping layer (5) together; C) Bonding the damping layer (5) to the stability layer (4), preferably by means of pressing and / or laminating; D) Bonding the stability layer (4) to an upper layer structure (3), preferably by means of pressing and / or laminating.

11. Method according to claim 10, characterized in that the method steps B) and C) and / or C) and D) are carried out simultaneously.

12. Method according to any one of claims 10 or 11, characterized in that the upper layer structure (3) has been provided before bonding with the stability layer (4) or is produced when bonding with the stability layer (4).

13. Method according to one of the claims 11-12, characterized in that first the carrier plate (6), the damping layer (5) and the stability layer (4) are adhered to each other and subsequently pressed with the, in particular resinated, upper layer structure (3) and optionally the, preferably resinated, countermove (15) or subsequently the upper layer structure (3) and optionally the countermove (15) is / are laminated or in that first the, in particular resinated, upper layer structure (3) is pressed with the stability layer (4) and optionally the, preferably resinated, countermove (15) is pressed with the carrier plate (6) and then the damping layer (5) is adhered with the stability layer (4) and the carrier plate (6).

14. Method according to one of the claims 10-13, characterized in that at least one preproduct (16) is provided and preferably temporarily stored, the preproduct (16) being obtained by bonding the damping layer (5), the stability layer (4) and the upper layer structure (3) or by bonding the carrier plate (6) to the damping layer (5) or by bonding the stability layer (4) to the upper layer structure (3) or by bonding the carrier plate (6), the damping layer (5) and the stability layer (4).