Plate-shaped building element and method for producing plate-shaped building elements

Abstract

The invention relates to a panel-shaped building element (1), in particular a floor panel, and a method for manufacturing such building elements (1). The building element (1) has a carrier panel (8) and a top surface wear layer (13). According to the invention, the carrier panel (8) is made from a multi-layer panel (2) from a second-hand product. A multi-layer panel (2) from a second-hand product can be a used laminate flooring element. It can also be B-grade goods or multi-layer panels from overproduction or discontinued collections. The multi-layer panels (2) from a second-hand product are collected and sorted and used to manufacture carrier panels (8) for panel-shaped building elements (1). For this purpose, the multi-layer panels (2) are trimmed at the edges. The wear layer (13) is applied to a top surface (11) of the carrier panel (8) manufactured from the multi-layer panel (2). A counter-layer (14) can also be applied to the underside.The side edges (15, 16) of the carrier plate (8) are profiled and connecting elements (17, 18) are formed on the side edges (15, 16).

Description

[0001] The invention relates to a plate-shaped building element, in particular a floor panel, which has a carrier plate and a top-side wear layer, as well as a method for producing plate-shaped building elements.

[0002] Surface coverings, such as flooring, come in a wide variety of designs. Panel-like building elements in the form of laminate are widely used. This is a multi-layer panel with a core made of compacted fiber materials. A multi-layer decorative layer is applied to the upper surface of the core. The decorative layer can include a resin-coated decorative paper and determines the appearance of the laminate. The so-called overlay or sealant forms a specially resin-coated wear layer that gives the floor panel a high level of surface durability. A counter-layer is applied to the underside of the core. This serves to ensure dimensional stability and act as a moisture barrier.

[0003] Typically, a laminate floor consists of several rows of rectangular floor panels. On one long side and one end, the floor panel has continuous grooves, and on the opposite long side and end, continuous tongues that are adapted to the grooves. The floor elements are installed by connecting the tongue and groove. Today, floor panels are predominantly connected using a so-called click system. These involve mechanical fasteners on the grooves and tongues that engage with each other when adjacent floor panels are installed in a floor covering. This allows for glue-free installation of the floor panels. Furthermore, the aim is to prevent the formation of gaps in the installed surface covering due to expansion and shrinkage.

[0004] Sooner or later, surface coverings will be replaced, whether due to wear and tear or renovation. This raises the question of how to dispose of the surface coverings, especially with floor coverings such as laminate flooring. Recycling is generally unproblematic if the components are made of wood and free of chloride or PVC. Modern technical processes make it possible to recycle laminate flooring. The laminate is broken down into wood fibers and chips, which are then fed back into the manufacturing process. This makes sense, especially from an ecological perspective. Thus, laminate flooring contributes to the development of a more circular economy. In the future, however, even more extensive reuse and reuse of panel-shaped building elements, especially laminate, is also desirable.

[0005] The invention is based on the object of creating an ecologically advantageous plate-shaped building element and of demonstrating a method for producing such building elements.

[0006] The solution to the present part of the problem is shown in claim 1.

[0007] The method according to the invention is the subject of claim 10.

[0008] A panel-shaped structural element according to the invention is, in particular, a floor panel. The structural element comprises a carrier plate and a wear layer on the upper side.

[0009] According to the invention, the carrier plate is made from a multilayer panel from a second use. A multilayer panel from a second use can be a used or previously used building element, in particular a laminate flooring element. A multilayer panel from a second use can also be a second-quality panel or a second-choice panel. Multilayer panels from overproduction or discontinued collections can also be repurposed according to the invention and used to produce the carrier plate of a building element according to the invention.

[0010] The invention creates a further use for multilayer panels through their secondary use and enables the creation of a new product from old, used or damaged multilayer panels, as well as from multilayer panels from overproduction or discontinued collections. Waste is reduced and the environment is protected. The invention creates an ecologically advantageous panel-shaped building element with sustainable and economic added value for manufacturers and consumers.

[0011] The base plate can consist of a laminate flooring element, a wood-based material, a polymer plastic material or a mineral mixture.

[0012] The multilayer panel has a decorative layer on its top side. This layer is specifically constructed in multiple layers. The multilayer panel has a counter-layer on its underside. The multilayer panel from a second use is reprocessed into a carrier board. Both the top and bottom sides can be mechanically processed, especially cleaned.

[0013] The processing of the multilayer panel into a carrier board involves, in particular, trimming the edges of the multilayer panel. This involves removing the original fasteners at the side edges of the multilayer panel.

[0014] Following the trimming or sawing process, the components are cleaned. In particular, the top and bottom surfaces can be cleaned using a brush station if necessary and then dried. Furthermore, cleaning agents with antibacterial additives or odorous substances can be applied to the panel body.

[0015] After cleaning and further processing or preparation, in particular by applying an adhesion promoter or primer to the upper surface of the carrier board, a wear layer is applied to the upper surface. The previously used product, i.e., the multi-layer panels from a second use, forms the carrier board for a new panel-shaped building element. For this purpose, the carrier board is recoated or covered on at least one side. This is done on systems that perform board lamination or coating. This can be done using PUR adhesives, PUR hot melt, permanent pressure-sensitive adhesives, reactive adhesives, especially two-component adhesives, or water-based or aqueous adhesives that cure through IR drying or hot press contact. Depending on the adhesive system used, a prior application of an adhesion promoter, in particular an adhesion primer, to the old surface to be coated is advisable.

[0016] The lamination of the layers of the panel-shaped component according to the invention, in particular the carrier plate and the wear layer, and optionally the backing layer, can be carried out by wet lamination, dry lamination, or thermal lamination. Individual panel-shaped components can be laminated one after the other, or several panel-shaped components can be laminated simultaneously.

[0017] Laminate floors or laminate flooring elements usually have more or less pronounced textures on their upper surfaces. These can be disadvantageous in terms of adhesion and / or lamination for the newly applied wear layer. Surface textures can also become visible on the upper surface. Therefore, it is advantageous to apply the wear layer to the previous underside of the multi-layer panel. In contrast to the old, good side, the original underside is usually smooth and less prone to adherent film of care products or dirt.

[0018] The wear layer can have different structures. In particular, the wear layer is multi-layered. Films, especially decorative films, but also real wood veneers and similar materials can be used to form the wear layer. However, films and adhesives that do not exert tensile stress on the product and do not affect the flatness of the building element are preferred. For sustainability reasons, PVC-free systems are particularly suitable. Because laminate flooring is manufactured with a counterlayer and decorative layer, its construction makes it very dimensionally stable, meaning the decorative recoating to create the wear layer of the flooring element can only be applied to one side. The original decorative layer can also function as a counterlayer.

[0019] A particularly advantageous embodiment provides that the carrier plate is provided with a counter-pull on the underside.

[0020] In a subsequent processing step, the carrier plate is profiled along at least two opposite parallel side edges, whereby connecting means are formed on the side edges.

[0021] It is particularly advantageous to have the original underside of the multilayer panel form the top side of the carrier plate. This is particularly advantageous because the original underside is usually very smooth and is subject to little, if any, wear during use. The original underside requires little machining to serve as the top side of the component's carrier plate.

[0022] The wear layer of the panel-shaped building element according to the invention is preferably multi-layered. It comprises one or more decorative layers, in particular a decorative paper or a decorative film, as well as an overlay or sealant that imparts high surface durability to the building element. A counterlayer is applied to the underside of the carrier plate. This serves to ensure dimensional stability and protect against moisture. Depending on the design, impact sound insulation can be provided on the underside of the carrier plate.

[0023] Connecting elements are provided on the side edges of the support plate. These connecting elements are preferably designed with click or snap-in connection elements.

[0024] The wear layer may include a decorative film. Such a decorative film is preferably made of polyethylene terephthalate (PET), polypropylene (PP), or polyolefin (PO) and is printed on at least one side.

[0025] Laminate flooring and laminate flooring elements, in particular, are very well-suited as multi-layer panels for secondary use. The laminate flooring elements have a closed surface, are robust and solvent-resistant, abrasion-resistant, and also flame-resistant. A further advantage is that laminate flooring largely has a similar structure regardless of the manufacturer. The decorative layer typically features an overlay of melamine paper with corundum components and a decorative paper. The core board is made of a highly compressed fiber material. The multi-layer panels have a counter-layer on the underside. Product thicknesses range from 6 mm to 10 mm in specific increments. Laminate flooring elements are equipped with a click connection and installed floating. Such planks or laminate flooring elements can be neatly removed at the end of their service life and returned to the manufacturer or reused.The dimensions are also generally largely the same regardless of the manufacturer. A typical and frequently used format has a width of between 192 mm and 197 mm and a length of between 1280 mm and 1380 mm. There are also tile formats with side dimensions of 300 mm x 400 mm or 400 mm x 850 mm. Long plank formats have a width of between 195 mm and 250 mm and a length of 1850 mm to 2200 mm. Of course, other dimensions are also available. These can also be used as multi-layer panels for secondary use. The multi-layer panels from secondary use are collected, sorted, and categorized by size. The edges are then trimmed. This involves cutting off the existing fasteners on all long sides and the front or end faces of the multi-layer panels.

[0026] For this purpose, the multilayer panels are fed into a sawing unit. The edge trimming takes place in the sawing unit, where the multilayer panels are cut to a uniform length and width. Trimming the multilayer panels is preferably brought to a uniform size, smaller than the smallest old plank size or the original size of the multilayer panels from a second use, in order to achieve the greatest possible material yield. The existing old fasteners or click profiles are removed on all sides.

[0027] Cleaning follows. In principle, cleaning could also be done beforehand. However, cleaning after the trimming process is advisable to remove cutting dust and similar debris.

[0028] The cleaning process may also involve mechanical action on one or both surfaces of the multilayer panels. This may involve sanding or brushing, particularly roughening the surfaces. Roughening the surfaces is beneficial to ensure good adhesion during subsequent bonding processes.

[0029] After the multi-layer panel has been processed into a core board, the wear layer is applied to the top surface of the core board. A bonding agent can be applied to this surface. The wear layer is then constructed, which is usually multi-layered and includes a decorative paper and / or a decorative film. An abrasion-resistant coating and / or a varnish forms the outermost wear layer of the wear layer on the top side.

[0030] The wear layer of the panel-shaped structural element according to the invention can also be a veneer layer made of real wood or a cork layer. The wear layer can be single-layered or multi-layered. An abrasion-resistant, transparent wear layer forms the surface of the wear layer.

[0031] Any material suitable for flooring or wall surfaces that can be applied and bonded to a base plate made of a multi-layer panel from a second use using a laminating agent is suitable as a wear layer. This allows for current interior design trends and furnishing styles to be accommodated.

[0032] An advantageous aspect of the invention provides that the underside of the multilayer panel from a secondary use is used as the upper side of the carrier plate of the panel-shaped building element according to the invention. For this purpose, the multilayer panel or the carrier plate reprocessed from the multilayer panel is turned over during the manufacturing process, and the original underside of the multilayer panel is used to construct the upper wear layer of the building element.

[0033] Optionally, the multilayer panel from a second use or the carrier board made from the multilayer panel can be treated with a disinfectant, especially on all sides, and / or an odorant can be applied to the multilayer panel from a second use or the carrier board. Odorants can be sprayed on, for example, or added as a component to the bonding agent, adhesive, or primer.

[0034] The invention enables the reuse of multilayer panels from a second use. Worn or no longer needed multilayer panels are given an attractive, modern, contemporary surface. Waste is avoided. Resources are saved. This results in both ecological and economic benefits.

[0035] One aspect of the invention provides that the plate-shaped components are provided with a marking, in particular a marking on the underside, from which the characteristic properties of a plate-shaped component are evident, in particular that it is a plate-shaped component from a second use. The marking makes it clear that the plate-shaped component is a second-life (2nd) product.

[0036] The invention is described in more detail below with reference to drawings.

[0037] The Figures 1 to 8show a technically schematic system for the reuse of multi-layer panels from a secondary use and a method for producing a plate-shaped building element according to the invention in the form of a floor panel.

[0038] The drawings are not to scale and should be understood as being proportional.

[0039] A plate-shaped building element 1 in the form of a floor panel is technically schematically shown in the Figure 8 shown.

[0040] To produce a panel-shaped building element 1, multilayer panels 2 are collected from a secondary use. The multilayer panels 2 used may be used products, as well as B-stock or multilayer panels 2 from overproduction or discontinued collections. An unordered number of multilayer panels 2 in different dimensions or sizes and dimensions is in the Figure 1 shown.

[0041] Such a multi-layer panel 2 is, in particular, a laminate flooring element. The multi-layer panel 2 comprises a panel body 3 made of a compacted, in particular highly compacted, wood-based fiber material, as well as a top-side decorative layer 4 and a bottom-side counter-layer 5 (see Figure 4 ). The multi-layer panel 2 has a top side 6 and a bottom side 7.

[0042] The multilayer panels 2 from a secondary use are sorted and categorized by size ( Figure 2 ). The multilayer panels undergo a quality inspection 2. This check focuses on flatness and technical properties, as well as the degree of contamination. Furthermore, they are sorted according to material thickness.

[0043] The multilayer panels 2 from secondary use are assessed for their suitability for use as a carrier plate 8 of a panel-shaped building element 1. Unusable multilayer panels 2 are sorted out and recycled elsewhere.

[0044] Sorted by size ( Figure 3 ) the multilayer panels 2 are fed to a processing unit to form the carrier plate 8. During processing, the edges of the multilayer panels 2 are trimmed. This is done in a sawing unit as shown in the Figure 4 is indicated schematically. When trimming the edges of the multi-layer panels 2, the old connecting elements 9,10 are separated from the multi-layer panels 2. This is shown in the Figure 4 shown.

[0045] The reconditioned multilayer panels 2 or the carrier plates 8 produced from them are cleaned. This may include surface treatment.

[0046] A carrier plate 8 is in the Figure 6 The carrier plate 8 still has the original multi-layer structure of the multi-layer panel 2 with the plate body 3, the decorative layer 4, and the counter-layer 5.

[0047] The carrier plate 8, reclaimed from the multilayer panel 2 from secondary use, is then sent for further processing. The carrier plate 8 can be turned over so that the original underside 7 of the multilayer panel 2 serves as the top side 11 of the carrier plate 8. This step is optional. The original top side 6 of the multilayer panel 2 can also be used as the top side 11 of the carrier plate 8.

[0048] When displaying according to the Figure 7 the original top side 6 of the multi-layer panel 2 forms the bottom side 12 of the carrier plate 8, whereas the original bottom side 7 of the multi-layer panel 2 forms the top side 11 of the carrier plate 8.

[0049] A wear layer 13 is applied to the upper side 11 of the carrier plate 8. For this purpose, an adhesion promoter has been applied to the upper side 11. The wear layer 13 is then completed. The wear layer 13 can comprise a layer of real wood veneer, cork, fabric or woven material, decorative paper, and / or a decorative film. Particularly preferably, the panel-shaped component 1 according to the invention has a film-based wear layer 13. Decorative films are used here, which are preferably made of polyethylene terephthalate (PET), polypropylene (PP), or polyolefin (PO). The decorative films are printed on at least one side. Such decorative films are available ready for use.

[0050] The application of the wear layer 13, including an outer top-side wear layer, can be carried out in a press, in particular a surface press. This takes place in individual element production, wherein the top side of the carrier plate 8 is provided with an adhesion promoter and the wear layer 13. Individual carrier plates 8 can be connected one after the other, or several carrier plates 8 can be connected in parallel or simultaneously, each with a wear layer 13. This can be done by wet lamination, dry lamination, or thermal lamination. The connection can be made using heat or heat and pressure, or by pressure and longer pressing times. In this case, individual plate-shaped components can be pressed one after the other, in parallel, or positioned one above the other.

[0051] In particular, the adhesion promoter is an adhesive that is applied in film form or as a hot-melt adhesive. A water-based adhesive can also be applied to the top surface.

[0052] A prefabricated surface covering is applied to the adhesion promoter layer as a wear layer 13. The wear layer 13 is joined on top. In particular, the wear layer 13 can be joined to the carrier plate 8 in a pressing or rolling process. The wear layer 13 can be stored on a roll, unrolled, and joined to the carrier plate 8. The wear layer 13 is cut from the roll in required lengths and fixed to the top side 11 of the carrier plate 8. The application of the wear layer 13 can be a classic roll lamination process or a wrapping process.

[0053] A counter layer 14 is applied to the underside of the carrier plate 8. The new counter layer 14 is applied to the original decorative layer 4 on the upper side 6 of the multi-layer panel 2.

[0054] The carrier plates 8, provided with the wear layer 13, are then stacked and cured. In a subsequent process step, the edge profiling of the carrier plate 8 takes place. The carrier plates 8 are profiled along at least two opposing parallel side edges 15, 16. This is done by mechanical processing, with connecting means 17, 18 being formed on the side edges 15, 16.

[0055] The invention provides a system for reusing multilayer panels 2 from a secondary use. This method creates new, panel-shaped building elements 1 in a cost-effective manner with a low carbon footprint. The carrier panels 8 made from a multilayer panel 2 already contain all barrier layers. A thin, structured wear layer 13 with a new surface decoration is applied to the top. In this way, multilayer panels 2 from a secondary use can be reused for many years, both in residential and commercial applications. Reference symbol:

[0056] 1 - Construction element 2 - Multi-layer panel 3 - Panel body 4 - Decorative layer 5 - Counter layer 6 - Top of 2 7 - Bottom of 2 8 - Support layer 9 - Fasteners 10 - Fasteners 11 - Top of 8 12 - Bottom of 8 13 - Wear layer 14 - Counter layer 15 - Side edges 16 - Side edges 17 - Fasteners 18 - Fasteners

Claims

1. A panel-shaped building element (1), in particular a floor panel, which has a carrier plate (8) and a top-side wear layer (13), characterized in that the carrier plate (8) is made from a multi-layer panel (2) from a secondary use, wherein the multi-layer panel (2) has a decorative layer (4) on the upper side and preferably a counter-layer (5) on the lower side, and wherein the original underside (7) of the multi-layer panel (2) or the original upper side (6) of the multi-layer panel (2) forms the upper side (11) of the carrier plate (8) onto which the wear layer (13) is applied.

2. Component according to claim 1, characterized in that the carrier plate (8) consists of a laminate flooring element, a wood material, a polymer plastic material or a mineral mixture.

3. Component according to claim 1 or 2, characterized in that the wear layer (13) is constructed in several layers.

4. Component according to one of claims 1 to 3, characterized in thatthe wear layer (13) comprises a decorative paper and / or a decorative film.

5. Component according to one of claims 1 to 4, characterized in that the wear layer (13) has a decorative film, wherein the decorative film consists of polyethylene terephthalate (PET), polypropylene (PP) or polyolefin (PO) and is printed on at least one side.

6. Component according to claim 5, characterized in that the decorative film has an abrasion-resistant coating and / or a varnish on the top side.

7. Component according to one of claims 1 to 6, characterized in that connecting means (17, 18) are provided on the side edges (15, 16) of the carrier plate (8).

8. Component according to claim 7, characterized in that the connecting means are designed with click and / or snap-in connecting elements.

9. Component according to one of claims 1 to 8, characterized in that a counter-pull (14) is provided on the underside of the carrier plate (8).

10. A method for producing panel-shaped building elements (1), in particular floor elements, comprising the following steps: - providing a multi-layer panel (2) from a secondary use, wherein the multi-layer panel (2) has a decorative layer (4) on the upper side and preferably a counter-layer (5) on the lower side; - processing the multi-layer panel (2) to form a carrier plate (8); - applying a wear layer (13) to an upper side (11) of the carrier plate (8), wherein either the original underside (7) of the multi-layer panel (2) or the original upper side (6) of the multi-layer panel (2) is used as the upper side (11) of the carrier plate (8); - profiling the carrier plate (8) along at least two mutually opposite parallel side edges (15, 16) and forming connecting means (17, 18) on the side edges (15, 16).

11. Method according to claim 10, characterized in thatthe processing of the multilayer panel (2) comprises one or more of the following processing steps: - surface processing of the multilayer panel, in particular cleaning, brushing and / or sanding a surface of the multilayer panel (2); - edge trimming of the multilayer panel (2); - application of a layer or coating, in particular an adhesion promoter, to a surface of the multilayer panel (2).

12. Method according to claim 10 or 11, characterized in that the wear layer (13) is formed in several layers.

13. Method according to one of claims 10 to 12, characterized in that a counter-pull (14) is applied to the underside of the carrier plate (8).

14. Method according to one of claims 10 to 13, characterized in thatthe multi-layer panel (2) from a secondary use or the carrier plate (8) made from the multi-layer panel (2) is treated with a disinfectant, in particular treated on all sides, and / or an odorous substance is applied to the multi-layer panel (2) from a secondary use or the carrier plate (8).

15. Method according to one of claims 10 to 14, characterized in that the plate-shaped components (1) are provided with a marking, in particular a marking on the underside, from which the characteristic properties of a plate-shaped component (1) can be derived, in particular that it is a plate-shaped component (1) from a secondary use.

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