Method for producing a decorative wall- or floor panel

Patent metadata

Field	Value
Publication number	US-12325167-B2
Application number	US-202017782816-A
Country	US
Kind code	B2
Filing date	Sep 25, 2020
Priority date	Dec 11, 2019
Publication date	Jun 10, 2025
Grant date	Jun 10, 2025

Abstract

The present disclosure relates to a method for producing a decorative wall- or floor panel, having the method steps: •a) providing a melted polymer mass; •b) extruding the molten polymer mass through a nozzle; •c) finish-sizing the molten polymer mass to form a panel-like carrier material by means of an assembly of multiple rotatable rolls, wherein the individual rolls are disposed one above the other or one behind the other and each individual roll forms at least one finish-sizing nip with neighbouring rolls, through which nip the melted polymer mass is passed, and wherein the finishing nip heights can be variably adjusted by a horizontal and/or vertical movement of individual rolls during the production process; •d) applying a decor pattern that imitates a decor template to at least one sub-region of the at least partly finish-sized carrier material, and •e) applying a protective coating to at least one sub-region of the decor.

First claim

The invention claimed is:

1. A method for producing a decorated wall or floor panel, comprising the method steps:
a) providing a melted polymer mass;
b) extruding the melted polymer mass through a die;
c) finish-sizing the melted polymer mass to form a carrier plate by means of an assembly of a plurality of rotatable rollers, wherein the individual rollers are arranged one behind the other and each individual roller forms with adjacent rollers at least one finish-sizing nip through which the melted polymer mass is passed, wherein the finish-sizing nip heights are variably adjustable by a horizontal and/or vertical movement of individual rollers during the production process;
d) applying a decoration reproducing a decoration template onto at least one sub-region of the at least partially finish-sized carrier; and
e) applying a protective coating to at least a sub-region of the decoration, wherein the finish-sizing in method step c) is carried out by use of at least one main roller pair consisting of two rollers with a larger diameter and at least three finish-sizing rollers arranged one behind the other with a smaller diameter compared to that of the main roller pair, wherein the height of the finish-sizing nip of the main roller pair H H differs from the heights of the finish-sizing nips of the finish-sizing rollers H K by greater than or equal to 10% and less than or equal to 50%, and wherein the height of the last and/or the penultimate finish-sizing nip is selected such that the carrier is compressed in its height by a factor of less than or equal to 10% and greater than or equal to 3%.

2. The method according to claim 1 , wherein method step d) prior to the application of the decoration additionally comprises the application of a decoration subsurface onto at least a sub-region of the carrier.

3. The method according to claim 2 , wherein at least the application of the decoration subsurface onto a sub-region of the carrier in method step d) takes place upstream of the last roller of the roller assembly of method step c).

4. The method according to claim 1 , wherein the roller assembly comprises, in addition to the main roller pair, at least four further finish-sizing rollers, wherein one of the roller nips of the finish-sizing rollers is operated isobarically.

5. The method according to claim 1 , wherein the main rollers and the finish-sizing rollers are equipped to be temperature-controlled and the temperature-controlled surface of the finish-sizing rollers is greater by a factor of greater than or equal to 1.1 up to less than or equal to 2.5 compared to that of the main rollers.

Assignees

• Akzenta Paneele Profile Gmbh

Inventors

• Hannig Hans-Jürgen
• Hoff Egon
• Hüllenkremer Felix

Classifications

• B29C2043/467

  plurality of rollers arranged in a specific manner in relation to each other · CPC title

• B32B2607/00

  Walls, panels · CPC title

• B32B2272/00

  Resin or rubber layer comprising scrap, waste or recycling material · CPC title

• B32B2264/107

  Ceramic · CPC title

• B32B2255/26

  Polymeric coating · CPC title