Carrier material on the base of a plastic composition and a mineral based solid composition for decorated wall or floor panels

Patent metadata

Field	Value
Publication number	US-11186709-B2
Application number	US-201916430854-A
Country	US
Kind code	B2
Filing date	Jun 4, 2019
Priority date	Jun 5, 2018
Publication date	Nov 30, 2021
Grant date	Nov 30, 2021

Abstract

A carrier material for producing a decorated wall or floor panel, as well as the corresponding wall or floor panel, may comprise a matrix material and a solid material. The matrix material is present from ≥25 wt.-% to ≤55 wt.-% and the solid material is present from ≥45 wt.-% to ≤75 wt.-% of the carrier material. The matrix material and the solid material together may be present in an amount of ≥95 wt.-% of the carrier material. The solid material is formed to at least 50 wt.-% of a solid composition consisting of at least a first layered silicate powder and a second layered silicate powder. The matrix material is formed to at least 50 wt.-% by a plastic composition consisting of a homopolymer and at least a first copolymer and a second copolymer.

First claim

The invention claimed is:

1. Carrier material for producing a carrier for a decorated wall or floor panel, wherein the carrier material comprises a matrix material and a solid material, wherein the matrix material, based on the carrier material, is present in an amount from ≥25 wt.-% to ≤55 wt.-%, and wherein the solid material, based on the carrier material, is present in an amount from ≥45 wt.-% to ≤75 wt.-%, and wherein the matrix material and the solid material together, based on the carrier material, are present in an amount of ≥95 wt. %,
wherein the solid material, based on the solid material, is formed to at least 50 wt.-% of a solid composition comprising at least a first layered silicate powder and a second layered silicate powder, and the matrix material, based on the matrix material, is formed to at least 50 wt.-% by a plastic composition comprising a homopolymer and at least a first copolymer and a second copolymer, wherein the solid composition comprises the first layered silicate powder from ≥35 wt.-% to ≤85 wt.-%, based on the solid composition, in the form of particles having a particle size D 50 in a range from ≥3 μm to ≤6 μm, and/or having a particle size D 98 in a range from ≥10 μm to ≤30 μm, and
comprises the second layered silicate powder from ≥15 wt.-% to ≤65 wt.-%, based on the solid composition, in the form of particles having a particle size D 50 in a range from ≥6 μm to ≤10 μm, and/or having a particle size D 98 in a range from ≥20 μm to ≤40 μm.

2. Carrier material according to claim 1 , wherein the first layered silicate powder and/or the second layered silicate powder comprise talcum.

3. Carrier material according to claim 1 , wherein the homopolymer, the first copolymer and the second copolymer comprise polypropylene.

4. Carrier material according to claim 1 , wherein the first copolymer comprises a heterophasic polypropylene and the second copolymer comprises an ethylene-propylene copolymer and an isotactic polypropylene.

5. Carrier material according to claim 1 , wherein the second copolymer has an ethylene content from ≥8 wt.-% to ≤22 wt.-%.

6. Carrier material according to claim 1 , wherein the melt flow rate of the homopolymer is greater than the melt flow rate of the first copolymer and the second copolymer.

7. Carrier material according to claim 1 , wherein the melt flow rate of the second copolymer is greater than the melt flow rate of the first copolymer.

8. Carrier material according to claim 1 , wherein the homopolymer, based on the plastic composition, is present in a proportion from ≥10 wt.-% to ≤40 wt.-% and/or that the first copolymer, based on the plastic composition, is present in a proportion from ≥40 wt.-% to ≤70 wt.-% and/or that the second copolymer, based on the plastic composition, is present in a proportion from ≥10 wt.-% to ≤40 wt.-%.

9. Carrier material according to claim 1 , wherein the matrix material in addition to the plastic composition comprises at least one coloring additive.

10. Carrier material according to claim 8 , wherein the coloring additive is a pigment preparation based on thermoplastic carrier materials, which has a temperature resistance up to at least 230° C. and a melting range from 95° C. to 125° C.

11. Carrier material according to claim 1 , wherein the matrix material comprises polyethylene in the form of LDPE.

12. Carrier material according to claim 1 , wherein the solid material in addition to the solid composition comprises at least one further solid.

13. Carrier material according to claim 11 , wherein the further solid has a bulk density in a range of ≤2000 kg/m 3 and/or that the further solid is selected from the group consisting of wood, expanded clay, volcanic ash, pumice, cellular concrete, inorganic foams and cellulose.

14. Decorated panel, in particular decorated wall or floor panel, comprising a carrier and a decoration applied onto the carrier, wherein in particular a covering layer provided with a structure is applied onto the decoration,
wherein
the carrier comprises a carrier material according to claim 1 .

Assignees

• Akzenta Paneele Profile Gmbh

Inventors

• Hannig Hans-Jürgen
• Hoff Egon

Classifications

• B29C2043/483

  cooperating with a second endless belt, i.e. double band presses · CPC title

• B27N3/08

  Moulding or pressing (presses in general B30B) · CPC title

• B44C5/0461

  used as wall coverings · CPC title

• C08L2205/025

  containing two or more polymers of the same hierarchy C08L, and differing only in parameters such as density, comonomer content, molecular weight, structure · CPC title

• C08L2205/03

  containing three or more polymers in a blend · CPC title