Method for producing a decorated wall or floor panel

Patent metadata

Field	Value
Publication number	US-10059072-B2
Application number	US-201414419798-A
Country	US
Kind code	B2
Filing date	Jul 18, 2014
Priority date	Jul 22, 2013
Publication date	Aug 28, 2018
Grant date	Aug 28, 2018

Abstract

A method for producing a decorated wall or floor panel, comprising placing a pourable granulate carrier material between two belt-like conveyors; molding the carrier material under the influence of temperature while forming a web-like carrier; compressing the carrier; treating the carrier under the influence of temperature and pressure by use of a dual-belt press; cooling the carrier; applying a decor simulating a decorative template onto at least a portion of the carrier; and applying a protective layer onto at least a portion of the decor. A wall or floor panel that is particularly stable, adaptable and high quality. An apparatus comprising elements for performing this method. A wall or floor panel comprising a plate-shaped carrier comprising a connecting element edge profile.

First claim

The invention claimed is:

1. Method for producing a decorated wall or floor panel, comprising the process steps of:
a) providing a pourable carrier material which is granulate;
b) placing the carrier material between two belt-like conveyor means;
c) molding the carrier material under the influence of temperature while forming a web-like carrier;
d) compressing the carrier;
e) treating the carrier under the influence of temperature and pressure by use of a dual-belt press to compress the carrier by a factor of >0% up to 7%;
f) cooling the carrier;
g) applying a decor subsurface onto at least a portion of the carrier, said decor subsurface being formed from a liquid radiation curable mixture based on a urethane or urethane acrylate, optionally with one or more of a photo initiator, a reactive diluent, a UV stabilizer, a rheological agent, radical scavengers, leveling agents, antifoams, preservatives, pigment, and a dye, said liquid being applied to the carrier in an amount between >1 g/m 2 and <100 g/m 2 ;
h) applying a decor simulating a decorative template onto at least a portion of the decor subsurface applied onto the carrier;
i) applying a protective layer onto at least a portion of the decor;
j) optionally texturing the protective layer for producing pores and/or the edge region of the carrier for forming connecting elements; and
k) optionally treating the carrier for inducing an electrostatic discharge prior to any one of the above process steps.

2. The method according to claim 1 , characterized in that the carrier material is based on a plastic material or based on a wood plastic composite material.

3. The method according to claim 2 , characterized in that the carrier material is based on a WPC material comprising wood and polyethylene, wood and polypropylene, or wood and a copolymer of polyethylene and polypropylene.

4. The method according to claim 2 , characterized in that the carrier material is based on a PVC material.

5. The method according to claim 1 , characterized in that the carrier material comprises wood and/or chalk having a particle size between 0 and ≤600 μm and a particle size distribution of D50≥400 μm.

6. The method according to claim 1 , characterized in that the carrier material comprises hollow microspheres.

7. The method according to claim 1 , characterized in that the pourable carrier material has a full width half maximum of the particle size in a range of ≥1.8 mm.

8. The method according to claim 1 , characterized in that a fiber material web, is incorporated into the carrier.

9. The method according to claim 1 , characterized in that a temperature gradient is set in process step c).

10. The method according to claim 1 , characterized in that process step d) is carried out by use of a S-roll, and is a separate operation from step (c) and performed after step (c).

11. The method according to claim 1 , characterized in that the carrier is compressed in process step e) by a factor of >0% up to 5%.

12. The method of claim 1 wherein steps g, j, and k are affirmatively performed.

13. The method of claim 1 wherein each belt of the dual-belt press is guided by guide rollers which are spaced from each other by a distance of ≥1 m to ≤2 m.

14. The method of claim 1 wherein the carrier is compressed in step (e) by ≥1 mm to ≤2 mm.

15. The method of claim 1 wherein each belt of the dual-belt press is guided by guide rollers which are spaced from each other and there are heaters between the guide rollers on each side of the carrier.

16. The method of claim 1 wherein the subsurface formed from the liquid radiation curable mixture in step (d) consists of said urethane or urethane acrylate, optionally with one or more of the photo initiator, the reactive diluent, the UV stabilizer, the rheological agent, the radical scavengers, the leveling agents, the antifoams, the preservatives, the pigment, and the dye.

Assignees

• Akzenta Paneele Profile Gmbh
• Akzenta Paneale Profile Gmbh

Inventors

• Hannig Hans-Jürgen

Classifications

• B29K2001/00

  Use of cellulose, modified cellulose or cellulose derivatives, e.g. viscose, as moulding material · CPC title

• B44C5/0461

  used as wall coverings · CPC title

• B44C5/04 Primary

  Ornamental plaques, e.g. decorative panels, decorative veneers · CPC title

• E04F13/0866

  composed of several layers, e.g. sandwich panels or layered panels (layered products as such in general B32B; producing decorative panels or veneers B44C5/04; E04F13/0864, E04F13/0875 take precedence) · CPC title

• E04F15/04

  only of wood {or with a top layer of wood}, e.g. with wooden {or metal} connecting members (rollable parquet E04F15/16) · CPC title