EP2951007A1

EP2951007A1 - Support sheet for decorative panel

Info

Publication number: EP2951007A1
Application number: EP13799292.1A
Authority: EP
Inventors: Hans-Jürgen HANNIG
Original assignee: Akzenta Paneele and Profile GmbH
Current assignee: Akzenta Paneele and Profile GmbH
Priority date: 2013-01-29
Filing date: 2013-12-03
Publication date: 2015-12-09
Also published as: EP2759394A1; US20150368421A1; US9650483B2; WO2014117887A1; CN104936770A

Abstract

The invention relates to a support sheet for a decorative panel. The invention relates in particular to the use of a partially expanded plastic sheet as a support sheet for producing a decorative panel, said sheet being based on a polyolefin admixed with a filler. The invention also relates to a method for producing a sheet of this type and to the use thereof as a support sheet in a decorative panel.

Description

Support plate for decorative panel

The present invention relates to a carrier plate for a decorative panel. In particular, the present invention relates to the use of a teilgeschäumten plastic plate based on a filler-additive polyolefin as a support plate for producing a decorative panel. For the purposes of the invention, the term decorative panel is understood to mean wall, ceiling or floor panels which have a decor applied to a carrier plate. Decorative panels are used in a variety of ways, both in the field of interior design of rooms, as well as the decorative cladding of buildings, for example in exhibition construction. One of the most common uses of decorative panels is their use as floor coverings. The decorative panels often have a decor that is intended to recreate a natural material.

Examples of such simulated natural materials are wood species such as e.g. Maple, oak, birch, cherry, ash, walnut, chestnut, wenge or even exotic woods such as panga panga, mahogany, bamboo and bubinga. In addition, many natural materials such as stone surfaces or ceramic surfaces are modeled.

So far, such decorative panels are often produced as laminates, in which on a carrier plate with a desired decor pre-printed decorative paper is applied, which in turn is then applied a so-called overlay. After possibly still on the decorative paper opposite side of the support plate Gegenüber paper was applied, the resulting layer structure using suitable pressure and / or heat-activated adhesive is firmly bonded together.

Depending on the desired field of application of the decorative panels, these can be made of different materials. In particular, the material of the carrier can be selected depending on the field of application. For example, the support may be made of wood-based material unless the decorative panel is exposed to excessive moisture or weather conditions. On the other hand, if the panel is to be e.g. used in wet rooms or outdoors, the carrier may for example consist of a plastic.

Plastics which can be used in the production of corresponding panels are, for example, thermoplastics, such as polyvinyl chloride, polyolefms (for example polyethylene (PE), polypropylene (PP), polyamides (PA), polyurethanes (PU), polystyrene (PS), acrylonitrile). Butadiene-styrene (ABS), polymethylmethacrylate (PMMA), polycarbonate (PC), polyethylene terephthalate (PET), polyetheretherketone (PEEK) or mixtures or co-polymers thereof The plastics may contain conventional fillers, for example calcium carbonate (chalk), alumina, silica gel , Quartz flour, wood flour, gypsum, and they can also be dyed in a known manner.

For applying a decoration to the support plate or a plate-shaped support, it is known to apply a decorative paper printed with a corresponding decor to the plate-shaped support, e.g. by means of a previously applied to the plate-shaped carrier resin layer as a connecting means. In addition, it is known to provide decorative panels in the so-called direct printing with a decor.

For the purposes of the invention, the term "direct printing" does not apply the application of a decoration directly to the support of a panel or to a support applied to the support understood printed fiber material layer. Contrary to the conventional method, in which a previously printed with a desired decor decorative layer is applied to a carrier, the printing of the decoration takes place directly in the course of panel production in direct printing. In this case, different printing techniques, such as flexographic printing, offset printing or screen printing can be used. In particular, digital printing techniques, such as Inkj et- method or laser printing method can be used.

For the purposes of the invention, by the term fiber materials, materials such as e.g. Paper and nonwovens based on vegetable, animal, mineral or even artificial fibers to understand, as well as cardboard. Examples are fiber materials made from vegetable fibers, in addition to papers and webs of cellulose fibers, plates of biomass such as straw, maize straw, bamboo, foliage, algae extracts, hemp, cotton or oil palm fibers. Examples of animal fiber materials are keratin-based materials such as e.g. Wool or horsehair. Examples of mineral fiber materials are mineral wool or glass wool.

To protect the applied decorative layer wear or cover layers are applied above the decorative layer in the rules. A wearing and / or covering layer in the sense of the invention is a layer applied as an outer finish, which in particular protects the decorative layer from wear or damage by dirt, moisture or mechanical influences, such as, for example, abrasion.

In many cases it is provided that in such wear or cover layers a matching with the decor surface structuring is introduced. Under a matching with the decor surface structuring is to be understood that the surface of the decorative panel has a haptic perceptible structure, which corresponds in shape and pattern of the applied decor, so as to obtain a true to the original reproduction of a natural material also in terms of haptics. In order to expand the fields of application of said decorative panels, especially in wet rooms or outdoors, plastics have increasingly been used as a material for such carriers in addition to carriers based on wood materials lately as a material for the plate-shaped carrier. Such panels are known for example from International Patent Application WO 2010/023042 AI. A disadvantage of these plate-shaped carriers is that plastic used for the plate-shaped carrier, such as in particular polyvinyl chloride (PVC), increasingly in the focus of public criticism, since they may involve a problem potential relevant from an environmental point of view. Thus, for example, for the production of flexible PVC plasticizers, for example from the group of phthalates, must be added in an amount of 20-30 wt .-% in order to ensure the desired elasticity of the PVC material. Such additives, however, are critically evaluated in the wake of recent legal regulations, why the use of such substances is attempted to avoid.

Taking this into account, it is the object of the present invention to provide a decorative panel based on a plastic carrier, which is able to overcome the problems known from the prior art. Moreover, it is an object of the present invention to provide a method for the cost-effective production of a corresponding decorative panel.

We solves this problem by a decorative panel according to claim 1 and a method according to claim 10. Embodiments of the invention in the dependent claims and the further description.

With the invention, a Dekorpaneelträgerplatte based on a thermoplastic material, which is characterized in that the plate is made of a raw material, which in addition to the thermoplastic resin, a filler and a pore-forming agent and wherein the filler content in the raw material is between> 10 wt .-% and <60 wt .-%, preferably between> 20 wt .-% and <45 wt .-% and the support plate has a pore content between> 10 wt .-% and <45 wt .-%, wherein the pore content is calculated according to the formula I.

100 ^{P plate} * ^100®

P raw material where ppiam corresponds to the bulk density in kg / m ^{3 of} the decorative panel carrier plate and pRohmateriai the bulk density in kg / m ^{3 of} the raw material.

Surprisingly, it has been shown that a support plate exhibiting the mentioned features is outstandingly suitable for the production of decorative panels. In this case, such a support plate on the one hand meets the mechanical, optical, acoustic and haptic requirements for the production of a decorative panel, on the other hand, such a support plate is inexpensively available, which is an economic prerequisite for use in the competitive field of Dekorpaneelherstellung. It has been found, in particular, that partially foamed carrier plates have a sufficient mechanical load capacity for use as a floor plate with a pore content of between> 10% by weight and <45% by weight, even if the surface only has a thin coating in the region 0.2mm layer thickness is provided.

In particular, a decorative panel carrier plate according to the invention is characterized in that a decorative panel produced using the carrier plate according to the invention has a residual impression according to DIN EN 649 of <0.05 mm, preferably <0.01 mm. In addition, a decorative panel produced using a carrier plate according to the invention is a ball fall test according to DIN EN 438 from a height> 1000mm, preferably> 1400mm. Also shows a using a erfmdungs appropriate A decorative panel produced by the support panel has a penetration depth <0.15 mm in a fall test based on DIN EN 438 of 600 mm height with a steel ball weighing 224 g. In addition, show decorative panels produced using a carrier plate according to the invention due to the porosity a good impact sound insulation when using appropriate decorative panels as a floor covering.

According to one embodiment of the invention, the support plate has a mean pore diameter d ₅ o between> 20μιη and <150μιη, preferably between> 30μιη and <120μιη, more preferably between> 40μιη and <90μιη. It has been shown that the pore diameter of the pore former contained in the carrier plate by the pore former contained in the raw material has a decisive influence on the mechanical properties of the decorative panels produced using the carrier plate according to the invention.

According to a further embodiment of the invention, it may be provided that the thermoplastic material in the decorative panel carrier plate has at least one substituted or unsubstituted polyolefin. The term "substituted polyolefin" as used herein means an alkyl, aryl, heteroaryl and / or halogen-substituted polyolefin. The thermoplastic material preferably has a polyolefin which is selected from the group consisting of polyvinyl chloride (PVC), polyethylene (PE), polypropylene (PP), polyisobutylene (PIB), polybutylene (PB) or mixtures or copolymers thereof.

According to a particularly preferred embodiment of the invention, the plastic is substantially free of organic plasticizers, in particular free of phthalate-based plasticizers, such as. Diethylhexyl phthalate (DEHP) or dioctyl phthalate (DOP).

In a preferred embodiment of the invention it is provided that the filler is selected from the group consisting of chalk, talc, kaolin, kaolinite, mica, Wollastonite, dolimite, barite, quartz, barium sulfate, fluorite (fluorspar), calcium sulfate (gypsum), titanium dioxide, glass or mixtures of these. The filler may preferably have an average particle diameter d ₅ o <150μιη, preferably <100μm, more preferably <80μm, more preferably <50μm, in particular <ΙΟμιη, such as between 2μιη and 4μm on. In particular, it is preferred that the average particle diameter d ₅ o of the filler in a range between 0.1 to 1.5 x corresponds to the average pore diameter d ₅ o of the pores in the Dekorpaneelträgerplatte. When glass is used as the filler, it can be used particularly preferably as glass breakage and / or glass powder and / or in the form of glass microspheres. According to a preferred embodiment of the invention, the filler has a Mohs hardness in a range between> 2.0 and <7.0, preferably between> 2.0 and <4.0.

The proportion of closed-cell pores in the carrier plate is preferably> 50%, preferably> 70%, more preferably> 90%>. It has been found that, in particular, a closed-cell pore structure can contribute to improving the mechanical properties of a decorative panel produced using a carrier plate according to the invention.

For the formation of corresponding pores in the carrier plate according to the invention, all means are suitable which can ensure the formation of pores of corresponding pore structure and with a corresponding pore diameter. It is particularly preferred in this case that expanding microspheres are used as pore formers. For this purpose, it can be provided that the raw material for producing the decorative panel carrier plates according to the invention has expandable microspheres which expand under the action of heat. Such microspheres may for example consist of a thermoplastic material and be filled with a hydrocarbon. On exposure to heat, the volume of the sphere expands by a factor of 10 to 90, due to the hydrocarbon expanding in the interior Embodiment of the invention are used as pore-forming expanding microspheres, which under heat, a volume expansion between 1000% and 4500%, preferably 2000%) and 4000%). According to a further embodiment of the invention, it may be provided that the Dekorpaneelträgerplatte is made of raw material in which the pore-forming agent in a concentration between> 0.5 wt .-%> and <5 wt .-%>, preferably> 0.8 wt .-%> and <2 wt .-%>, more preferably> 1.0 wt .-%> and <1.8 wt .-%> is included.

Furthermore, the Dekorpaneelträgerplatte may contain auxiliaries such as stabilizers and / or pigments. In this case, stabilizers can be added in particular to improve the UV stability. It can also be provided that the panel comprises flame retardants such as, for example, polybrominated diphenyl ethers (PBDE), phosphorus-containing compounds and / or aluminum hydroxide.

According to a further preferred embodiment of the invention, the Dekorpaneelträgerplatte know a density> 800 g / m ³ . The density of the material on the one hand advantageous in terms of mechanical properties of the support plate, on the other hand, the density has an impact on the haptic sensation of the buyer, who assesses a heavier decorative panel as valent.

The present invention furthermore relates to a method for producing a decorative panel carrier panel according to the invention, comprising the method steps

a) mixing at least one granulated thermoplastic base material with at least one filler and at least one pore former;

b) applying the raw material produced in step a) to a press plate or introducing the raw material into an extruder; c) heating the raw material to a temperature between> 80 ° C and <220 ° C, preferably between> 80 ° C and <180 ° C and pressing the raw material at a pressure between> 0.5 kN / cm ² and <30 kN / cm ² , preferably between> 1 kN / cm ² and <10 kN / cm ^2, or calendering the polymer mass coming from the extruder to a desired backing plate thickness; and

d) recooling the plate to a temperature <80 ° C, preferably <70 ° C, more preferably <50 ° C,

for providing a decorative panel support plate. According to a preferred embodiment of the method, a double-belt press or a short-cycle press is used as the press. It is particularly preferred if the pressing surfaces comprise an inert, temperature-resistant plastic surface, such as e.g. have a polytetrafluoroethylene surface. The application of the raw material to a press plate can according to the invention, for example, by sprinkling, pour or inflate carried out on a press plate.

In this case, it is particularly preferred if the process for producing a decorative panel carrier plate is carried out as a continuous or semi-continuous process using a double-belt press in which the raw material is introduced into the mixture before, or in the inlet region of the press, pressed under heat supply and then recooled wherein the re-cooling is preferably carried out under pressure, particularly preferably while maintaining the pressing pressure. The endless plates thus produced are then cut to an intermediate dimension or the final dimension of the decorative panels. Likewise, it can be provided that the decorative panel carrier plates are already produced in the press at least with regard to a plane dimension, that is to say in terms of length or width, so that the carrier plate only has to be cut to length after pressing. It can heat up the raw material be provided that the heat transfer medium used for heating, such as press plates, press belts or extruder are heated to a temperature above the temperature to be reached of the raw material. For example, it can be provided that the heat transfer medium to a temperature between> 150 ° C and <300 ° C, preferably> 250 ° C are heated.

Following the production of the carrier plate, a direct further processing of the carrier plate to the decorative panel may preferably take place, wherein a decoration on the carrier plate directly or a printing substrate previously applied to the carrier plate preferably takes place using a direct printing method or a decorative film lamination. It is particularly preferred if the decor is applied by means of a digital printing process, preferably using radiation-curable inks. This allows the short drying or curing time of the color highly integrated design of the manufacturing process, starting from the raw material for the Dekorpaneelträgerplatte to the finished decorated panel.

Furthermore, it can be provided that a printing substrate is applied to the plate-shaped carrier before the application of the decorative layer. In this case, it may be provided, in particular, that a composition is applied as the printing substrate, which has, on the one hand, free-radically curing constituents and, on the other hand, polyurethane constituents, as is known, for example, from dual-cure coating systems. It may be provided in particular that the printing substrate contains urethane acrylates. In addition, the printing substrate may in particular contain pigments, such as, for example, titanium dioxide.

The application of the decor upstream or downstream profiling of the edges may be provided, in which introduced by means of example machining processes functional and / or decorative profiles at least along one edge of the support plate become. In this case, the functional profiles can be designed such that by means of this individual panels can be detachably connected together to form a connected laying surface when laying. Decorative profiles can be introduced, for example, to form a V-joint or country-house joint between two adjacent panels in the laying surface.

Furthermore, it can be provided according to the invention that a cover and / or wear protection layer is applied to the decor or the color layer forming the decor. In this case, it can be provided, in particular, that a wear-resistant lacquer layer, preferably based on a radiation-curable lacquer, is applied to the decorative-color layer and dried or cured. This also supports the integration of the manufacturing process into an in-line production process, at the end of which there is a finished decorative panel. Together with the decor-color layer or the decorative film and / or with the wear-resistant layer, a counter-pull can be applied to the opposite side of the decor of the support plate in order to prevent distortion of the panel, e.g. to avoid by so-called bowls. For this purpose, it can be provided in particular that a Gegenzugfolie or a lacquer layer is applied.

Furthermore, the invention relates to a decorative panel which has a carrier plate according to the invention and a decorative layer applied to at least one side of the carrier plate.

According to a preferred embodiment of the invention, the decorative panel between the support plate and the decorative layer, a printing substrate and / or on the decorative layer, a cover and / or wear protection layer and / or on the opposite side of the decorative layer of the support plate on a counter pull. It may be provided in particular that the cover and / or wear protection layer and / or the counter-pull are formed of a radiation-curable, preferably transparent or translucent composition.

According to a further embodiment of the invention, it may be provided that the decorative panel has a profiling at least in an edge region of the carrier plate. It may be provided in particular that the decor is also applied in the profiling, so that the profiling takes place before applying the decorative layer on the plate-shaped carrier. Alternatively or additionally, a profiling can also take place after the decorative layer has been applied. In a profiling according to the invention, it is provided that a decorative and / or functional profile is introduced by means of suitable material-removing tools at least in a part of the edges of the decorative panel. In this case, a functional profile is understood, for example, to mean the introduction of a tongue and / or groove profile into an edge in order to make decorative panels connectable to each other via the introduced profilings. A decorative profile in the sense of the invention is, for example, a chamfer introduced in the edge region of the decorative panel in order to simulate, for example, a joint between two interconnected panels, as occurs, for example, in so-called plank flooring.

In a partial profiling of the decorative panel not all to be provided in the final panel profiles are introduced, but only a part of the profiles to be provided, while other profiles are introduced in a subsequent step. For example, it may be provided that the decorative profile to be provided in a panel, such as a chamfer, is introduced in one work step, while the functional profile, for example tongue and groove, is introduced in a subsequent work step. By applying the decoration only after the at least partial profiling of the carrier, for example by the above-described methods such as direct printing method, a removal or damage of the decoration in the course of profiling is advantageously avoided. As a result, the decor also corresponds in the fields of profiling in a faithful manner the desired imitation example of a natural material.

Claims

claims

1. decorative panel carrier plate based on a thermoplastic material, characterized in that the plate is made of a raw material, which in addition to the thermoplastic material has a filler and a pore-forming agent and wherein the filler content in the raw material between> 10 wt .-% and <60 wt. %, preferably between> 20 wt .-% and <45 wt .-% and the support plate has a pore content between> 10 wt .-% and <45 wt .-%, wherein the pore content is calculated according to the formula I.

100 ^{P plate} * 100 ^

P raw material where ppiatte the bulk density in kg / m ^{3 of} the Dekorpaneelträgerplatte and p raw material corresponds to the apparent density in kg / m ^{3 of} the raw material.

2. Dekorpaneelträgerplatte according to claim 1, wherein the carrier plate has a mean pore diameter d ₅ o between> 20μιη and <150μιη, preferably between> 30μιη and <120μm, more preferably between> 40μm and <90μm.

3. decorative panel carrier plate according to one of the preceding claims, wherein the thermoplastic material comprises at least one substituted or unsubstituted Polyolefm.

4. decorative panel carrier plate according to one of the preceding claims, wherein the thermoplastic material comprises a Polyolefm which is selected from the group consisting of polyvinyl chloride (PVC), polyethylene (PE), polypropylene (PP), polyisobutylene (PIB), polybutylene (PB) or Mixtures or co-polymers of these.

5. decorative panel carrier plate according to one of the preceding claims, wherein the filler is selected from the group consisting of chalk, talc, kaolin, kaolinite, mica, wollastonite, dolimite, barite, quartz, barium sulfate, fluorite (fluorspar), calcium sulfate (gypsum), titanium dioxide , Glass or mixtures of these.

6. Dekorpaneelträgerplatte according to any one of the preceding claims, wherein the filler has a mean grain diameter d ₅ o <150μιη, preferably <ΙΟΟμιη, more preferably <80μιη, more preferably <50μιη, in particular <ΙΟμιη.

7. decorative panel carrier plate according to one of the preceding claims, wherein the proportion of closed-cell pores in the carrier plate> 50%, preferably> 70%, more preferably> 90%>.

8. Dekorpaneelträgerplatte according to any one of the preceding claims, wherein the carrier plate is made of a raw material which has expandable microspheres as a pore former.

9. decorative panel carrier plate according to claim 8, the pore-forming agent in the raw material in a concentration between> 0.5 wt .-%> and <5 wt .-%>, preferably> 0.8 wt .-%> and <2 wt .-% >, more preferably> 1.0 wt .-%> and <1.8 wt .-%> is contained.

10. A method for producing a Dekorpaneelträgerplatte according to any one of claims 1 to 9, comprising the method steps,

a) mixing at least one granulated and / or powdered thermoplastic base material with at least one filler and at least one pore former;

d) recooling the plate to a temperature <90 ° C, preferably <80 ° C, more preferably <70 ° C,

for providing a decorative panel support plate.

11. The method according to claim 10, wherein a double belt press or a short-cycle press is used as the press.

12. decorative panel, comprising a support plate according to one of claims 1 to 9 and a decor applied to at least one side of the carrier plate decorative layer.

13. decorative panel according to claim 12, wherein this between the support plate and the decorative layer, a printing substrate and / or on the decorative layer has a cover and / or wear protection layer and / or on the decorative layer opposite side of the support plate has a counter-pull.

14. decorative panel according to any one of claims 12 and 13, wherein the cover and / or wear protection layer and / or the counter-pull of a radiation-curable, preferably transparent or translucent composition is formed.

15. Decorative panel this has at least in an edge region of the plate-shaped carrier profiling and wherein the profiling is configured such that a plurality of decorative panels are releasably connected to each other by means of corresponding profiles.