EP2963204B1 - Panel for a floor, wall or ceiling lining or for a furniture component and method and press device for producing such a panel - Google Patents

Description

The invention relates to a plate for a floor, wall or ceiling covering or for a furniture component, preferably flooring, wall covering or ceiling panel or furniture component plate, with a flat support plate and an applied to the support plate upper layer.

Plates of the aforementioned type, which are also referred to as panels or planks, as far as the area floor, wall or ceiling is concerned, have long been known in practice. Plates of the aforementioned type for the area floor, wall or ceiling are usually provided on the edge side with a tongue and groove connection in order to be able to be laid securely on the ground to a corresponding surface. Such compounds are also referred to in practice as a bung or bung. As a rule, so-called click connections are used as connection technology of the plates. Plates with click-connections, which are usually connected to each other via a Einschwenkbewegung and locked together in the clicked state, for example, from DE 297 24 428 U1 known. In the known plates, the support plate is usually made of MDF, HDF, plastic or a ground, assembled with binder wood fiber.

Carrier panels for laminates, which are made of MDF or HDF, usually consist of about 82% spruce or pine with a share of sawed wood and about 11% urea resin, 5 to 7% water and 1% paraffin wax. The carrier plates are manufactured, transported, separated and profiled at great expense. The resulting chips are usually utilized thermally. A disadvantage of the known laminates or plates used for it is that the plate production is relatively complex overall and that for the production of HDF / MDF, a relatively high proportion of new wood is used.

From the DE 20 207 844 U1 a carpet flooring element is known. The carpet flooring element has a rectangular support plate, at the top of a suitably sized carpet is attached. To compensate Unevenness may be provided on the underside of the support plate, a nonwoven layer.

The DE 10 2013 101 797 A1 discloses a panel for a laminate or parquet flooring. The panel has a carrier plate comprising a load distribution layer. In addition, on the underside of the panel, a fleece may be attached, which consists of glass fibers, textile fibers or plastic.

The DE 10 2012 112 562 A1 relates to a floor element with a carrier plate of high-density cork. In addition, a decorative layer is applied as an upper layer on the carrier plate, wherein between the carrier plate and the decorative layer, a web-shaped carrier material, such as a non-woven, may be provided.

The WO 2014/053186 A1 relates to a floor panel for outdoor use. The floor panel has a plate formed by, for example, a fiber cement panel. In addition, a glass fleece may be provided on the underside of the carrier plate.

From the US 3,661,491 is a panel for isolation or decoration known. To produce the panel, a strand of a binder with glass fibers distributed therein as loose mass is fed continuously to a pressing device. In a press nip of the pressing device takes place under heat, a solidification and shaping of the strand, so that there is a substantially operational panel after passing through the press nip.

Object of the present invention is therefore to provide a plate of the type mentioned above and a related method available, making it possible to produce plates of the aforementioned type easier, cheaper and more environmentally sustainable.

The above object is achieved according to the invention in a plate of the type mentioned by the features in claim 1. The plate according to the invention has, in addition to the carrier plate, an upper layer applied to the carrier plate. The upper layer may be formed in one or more layers. The upper layer may have a decorative layer and / or a wear layer. The decorative layer can be applied to a decor carrier. The upper layer then has the decor carrier with the decorative layer and the wear layer. The decor carrier may be a printable (decorative) paper and / or a nonwoven layer and / or a carrier layer, preferably a film made of a plastic, in particular vinyl, PVC, PUR, PE or PP. If a nonwoven layer is provided as a decor carrier, this can be pressed with the carrier plate. In principle, a primer can also be applied as decor carrier to the carrier plate. The decorative layer is then applied to the primer. The wear layer may consist of a plastic, preferably of vinyl, PUR, PP, PE, or an oxidative or UV lacquer. Incidentally, adhesive layers may be provided between the decor carrier and the wear layer and / or between the decor carrier and the carrier plate. Below the decor carrier, a stabilizing layer of cork or a plastic material may be provided.

The transverse tensile strength of the carrier plate according to the invention according to EN 319 can be in the range from 1.0 to 4.0 N / mm ² , in particular in the range from 1.4 to 2.5 N / mm ² . The lift-off strength according to EN 311 may be in the range of 1.0 to 4.0 N / mm ² , preferably in the range of 1.5 to 2.8 N / mm ² . The pull-out strength in the presence of a click connection based on ISO 24334 can be in the range of 1.0 to 6.0 kN / m, preferably in the range of 2.5 to 5.0 kN / m. The pull-out strength is a value based on the length of the click joint, in particular based on a plate thickness of 1.0 cm or less. So you need, for example, 2.5 kN to pull apart a click connection of one meter in length. The abovementioned value ranges may also be exceeded in the case of the carrier plate according to the invention for the transverse tensile strength and / or the lift-off strength and / or the pull-out strength.

A non-woven fabric of the type according to the invention is understood to mean a structure of limited-length fibers, continuous filaments, also referred to as filaments, or cut fibers of any kind and origin, which have in some way been joined or bonded together to form a nonwoven fabric. The Length of the fibers is usually 30 to 90 mm for natural fibers, for synthetic fibers, the length is usually between 50 and 70 mm.

Nonwovens are usually flexible textile fabrics made of fibers that have a comparatively small thickness compared to their length and width.

In the context of the present invention, it has surprisingly been found that a consolidated, needled nonwoven fabric can easily meet the requirements usually imposed on a support plate, such as strength and stability. In addition, the use of a consolidated nonwoven fabric as a material of the support plate offers further significant advantages.

First of all, a nonwoven material is an alternative to wood or wood materials as a material of the support plate material that is very cost-effective and ecologically sustainable. In addition, the solidified nonwoven fabric provides very good acoustics and sound insulation properties, which can only be achieved when using a carrier plate made of a wood material, if in addition a soundproofing mat is provided in the laminate in question. In addition, the degree of solidification of the nonwoven fabric can produce a different ride for the user. A less strongly consolidated nonwoven fabric results in a softer ride, while a strongly consolidated nonwoven fabric results in a similarly hard ride as when using a wooden backing plate.

Furthermore, it has been shown that the processing and processing of the nonwoven carrier plate is much easier possible than in a carrier plate made of a wood material. First of all, much deeper structures can be achieved by compressing the nonwoven as a carrier plate in combination with resinated papers as a decorative layer if the surface structure is pressed directly during the pressing process of the carrier plate. In addition, it is in principle possible to pre-form or profile the groove-tongue or click geometry at the edge on the plate, so that the profiling effort and the associated costs can be reduced. Finally, a support plate made of a consolidated nonwoven material with respect to a support plate made of a wood material improved thermal insulation properties, in a support plate can be realized from a wood material only by a supplementary thermal barrier coating.

The abovementioned advantages arise at least partially even when the carrier plate has at least one layer of a consolidated non-woven fabric. In this alternative, the carrier layer may not be complete, but only partially made of a consolidated nonwoven fabric. For example, a layer of a consolidated nonwoven fabric and a layer of HDF or MDF may be provided. Also, a sandwich construction with an inner HDF or MDF layer and outer consolidated nonwoven fiber layers is possible in the same way as an internally solidified fiber fleece layer and outer HDF or MDF layers.

In principle, the non-woven fabric used for the carrier plate according to the invention can be made of any fibers that are commonly used for non-woven production. Thus, in principle, vegetable, animal, mineral and / or recycled fibers and fibers of natural and / or synthetic polymers in question. It is understood that mixtures of the aforementioned fibers in any combination are possible. If synthetic fibers are used, they consist predominantly of PP and / or PET and / or PE.

In a preferred embodiment of the present invention, which is particularly based on an ecological sustainability and thus takes into account that in the carrier plate production a considerable amount of waste is obtained, which should preferably be well usable, it is provided that the nonwoven fabric at least predominantly from vegetable fibers, especially from sustainable produced flax, kenaf and / or hemp fibers should exist.

In a particularly preferred embodiment, a nonwoven fabric made of a fiber mixture is used for producing the carrier plate, which comprises between 10 and 30% by weight, preferably between 20 and 25% by weight, of synthetic fibers, in particular of PP and / or PE. The fiber mixture may additionally comprise flax and / or kenaf fibers and / or other fibers. If this fiber mixture is highly densified, a very high water resistance is achieved compared to HDF boards. In the solidified state, the density of the compacted Fiber mixture after pressing preferably in the range between 700 and 900 kg / m ³ .

For solidification of the nonwoven fabric according to the invention, basically all known solidification methods can be used, which are also used in nonwoven production from a fiber raw material. The methods of mechanical, chemical or thermal solidification can each be used alone or in combination.

In the case of mechanical consolidation, the composite of the fibers is produced by frictional engagement or by a combination of frictional and positive locking. In the frictional connection, the distance of the adjacent fibers in the nonwoven base material is reduced by nonwoven compaction. This increases the adhesion of the fibers to each other and allows higher forces to be transmitted. The resistance of the nonwoven fabric against deformation becomes higher, while it becomes stronger at the same time. Compression can be achieved, for example, by shrinkage of all fibers or a proportion when the fibers are shrinkable on exposure to heat. Likewise, the compaction can be carried out by pressing, for example by means of calendering or by walking, in which the fibers of the nonwoven fabric according to the invention must be feltable and by simultaneous thermal, chemical and mechanical effects entangled with each other.

In the nonwovens made by combining friction and form-fitting binding, the fibers of the nonwoven fabric according to the invention are intertwined by mechanical effects. This is done by needling, by a plurality of special, arranged in a needle bed or beam needles and is punched out.

In the chemical solidification process, the composite of the fibers is achieved by material adhesion by means of additives. The bonding of fibers by means of additives, commonly referred to as binders, is also referred to as adhesive bonding. In the vast majority of chemical processes, the binder is applied in liquid form (eg polymer dispersions) to or in the nonwoven fabric and cured by subsequent heat treatment (drying, condensation, polymerization), whereby the nonwoven is solidified. The application of the liquid binder can, for example, by impregnation or spraying done. Typical binders may be, for example, acrylate resins, epoxy resins and / or melamine resins.

In the case of thermal consolidation, the composite of the fibers is likewise produced by material bonding, although a distinction is made between adhesive and cohesive composite. Prerequisite for the thermal consolidation are additional thermoplastic components, in particular in the form of thermoplastic fibers.

Preferably, a thermo-mechanical consolidation of the fiber composite is provided, wherein a fiber composite is compressed after prior needling of the fibers under the influence of heat, especially in a double belt press / belt press with preheating to warm the material. In particular, the fiber composite on plastic fibers, in particular PP and / or PE fibers on. The fiber mixture can also have hemp and / or flax and / or kenaf fibers. By supplying heat before and / or during the compression of the fibers, the fibers may at least partially melt, which leads to a high strength of the connection of the fibers during compaction. To solidify the fiber composite, double belt presses / belt presses with preheating for heating the fiber material can preferably be used.

In connection with the present invention, it has further been found that very good solidification properties are achieved when the nonwoven fabric is impregnated with binder, ie impregnated, and / or thermoplastic polymer fibers are contained in the nonwoven fabric.

In experiments in the context of the present invention, it has been found that very good properties of the consolidated from the consolidated nonwoven backing plate are achieved when the support plate has a greater proportion of solidified nonwoven material and a smaller proportion of binder and / or thermoplastic polymer fibers. The proportion of binder or thermoplastic polymer fibers is preferably not more than 50%, in particular 40%, and more particularly not more than 30% by weight. It is even possible to reduce the proportion of binder to 20 wt .-% or even less. In a particularly preferred embodiment of the invention is a mass ratio in the range of 75% by weight of nonwoven material and 25% in binder or thermoplastic polymer fibers.

Incidentally, it has been found that the proportion of binders may vary depending on the type of the binder. The percentage of thermoplastic binders should be higher for the same plate density and stability than the required percentage of resins as a binder.

In connection with the present invention, it has furthermore been found that it is particularly preferred to use as the starting material of the nonwoven fabric according to the invention, if it is not yet in the solidified state according to the invention, a nonwoven fabric whose density is between 80 kg / m ³ and 300 kg / m ³ , preferably between 100 kg / m ³ and 210 kg / m ³ and in particular between 150 kg / m ³ and 170 kg / m ³ should be. In the solidified state according to the invention, the density of the nonwoven fabric is between 400 kg / m ³ and 1000 kg / m ³ , in particular between 400 kg / m ³ and 900 kg / m ³ and particularly preferably between 750 and 850 kg / m ³ .

It should be pointed out in this context that it is basically possible to form the carrier plate in a multi-layered manner, wherein one layer of the carrier plate can have a greater density than the other layer. This will be discussed in more detail below.

In connection with the selection of the fibrous material according to the invention for the intended purpose for use as a carrier plate, the degree of compaction of the unconsolidated fibrous web to the consolidated fibrous web is between 10: 1 and 2: 1, preferably between 8: 1 and 4: 1, more preferably 7: 1 and 4: 1, and more preferably between 5: 1 and 4: 1.

Furthermore, it has been found in connection with strength and stability studies that the support plate according to the invention should have a thickness between 4 and 15 mm, preferably between 6 and 12 mm when used as a floor, wall or ceiling covering. When used as a furniture panel, the thickness of the support plate is preferably between 5 and 30 mm.

Incidentally, the support plate according to the invention, when used in the area of floor, wall and ceiling, as has already been indicated at the outset, on the edge side a tongue and groove contour preferably in the form of a click connection. During pressing of the fiber mixture, in particular after prior heating of the fiber material with the possibility of melting the fiber material in regions, a carrier plate is obtained, which has a compared to HDF plates substantially constant strength over the plate thickness. In particular, the fiberboards according to the invention do not have a soft middle layer, such as HDF boards, which makes it possible to introduce a stable click contour even in boards with a comparatively lower bulk density. In this context, the pull-out strength of a click connection in carrier plates according to the invention based on ISO 24334, a value between 1.5 and 6.0 kN / m ² , preferably between 2.5 and 5.0 kN / m ² , assume or even higher ,

In a particularly preferred embodiment of the invention, it is provided that the carrier plate is more strongly solidified in the region of the tongue and groove contour than outside the region of this contour. In this way, the locking profile can be made much more stable and the risk of damaging the groove and / or the spring is reduced.

Preferably, the carrier plate is formed in a multi-layered manner and / or has at least two layers with a different degree of compaction and / or solidification. Alternatively or additionally, the carrier plate may have at least one layer of HDF and / or MDF.

The higher degree of solidification in the region of the connection contour can be realized in different ways. On the one hand, it is possible to use a multilayer carrier plate, as already explained, in which a more strongly consolidated fibrous nonwoven layer is used in the region of the locking contour. The thickness of this sub-layer of the carrier layer is at least slightly greater than the maximum height of the groove of the locking contour, so that the groove can be completely formed within this more solidified carrier layer. Another alternative is to strengthen the nonwoven material in the area of the locking contour stronger. This area can already be more compacted in the production of the carrier plate in order to achieve a stronger solidification in this way.

It should be pointed out that the two alternatives mentioned above can also be used in combination with each other.

Incidentally, it has been determined according to the invention that further positive effects can be achieved by the multi-layered nature of the carrier plate. A multilayer carrier plate according to the invention is already present if the carrier plate has at least two layers which have a different degree of compaction and / or solidification. However, support plates with three, four, five or an even greater number of individual layers are also possible, wherein the individual layers can in principle all have different compaction and / or solidification degrees. However, at least two groups of layers are present, one group having a higher degree of solidification and compaction and / or the other group having a different degree in this respect.

Incidentally, it is understood that the different layers of the carrier plate can be made not only of one but also of different nonwoven materials.

In addition to achieving a special stability of the locking contour or alternatively, can be realized by choosing different layers of the support plate and a different elastic behavior of the plate. If, for example, a layer with a less strongly consolidated nonwoven fabric is used in combination with a layer with a more strongly consolidated nonwoven fabric, this can create a feeling of being perceived as very pleasant by the user. In such an embodiment, as the upper layer of the carrier plate, a more strongly consolidated nonwoven fabric should be realized, while underneath a layer with a less strongly consolidated nonwoven fabric is used. For example, a support plate could be constructed in three layers, which has an upper relatively strongly consolidated layer, an underlying, less strongly solidified and thus more elastic layer and underneath a turn stronger consolidated layer within which the locking contour is formed. The individual layers can, as stated above, consist of the same nonwoven material, wherein the stronger solidification is produced only due to different compaction, but it can also be different Nonwoven materials are used, which fulfill the aforementioned effect and function.

As has already been stated, it may of course also be provided to provide an inner HDF or MDF layer, for example 3 mm thick, and above and below each a consolidated fibrous nonwoven layer. In this embodiment, the locking contour can then be provided in the central HDF or MDF layer.

Furthermore, it has been found in the context of the present invention that it is advantageous if the upper layer is also formed multilayer. Thus, the upper layer may be a printed, resinated or non-resinated paper layer, in particular a decorative paper layer, a protective overlay, in particular of corundum, an outer wear layer of plastic, in particular vinyl, PUR or PP, a printed plastic support, in particular of vinyl, a lacquer layer, in particular a Structure lacquer layer, and / or have a printed nonwoven layer. In this context, it is possible to apply a further layer of another or the same nonwoven material on the carrier layer on the top side already during needling of the nonwoven fabric to be used for carrier plate production. This creates a printable layer directly. It is understood that combinations of the aforementioned layers with one or more of the aforementioned alternatives are readily possible.

By realizing the upper layer in the above-mentioned manner, it is ultimately possible to produce a plate which, on the outside or in the installed state, can not be distinguished from a plate known from the prior art with a carrier plate consisting of a wooden material, but otherwise complementary has the aforementioned improved properties and offers advantages.

Furthermore, the plate according to the invention has a lower layer, which is applied to the carrier layer on the underside. This lower layer can have different properties or ensure functions. On the one hand, the lower layer can serve as a counterweight or underlay in order to avoid any undesired distortion of the carrier plate according to the invention. In addition, can be achieved by a lower layer complementary soundproofing or acoustic properties, which are already on through the realization of the invention already resulting advantageous sound insulation and acoustic properties go beyond. For example, a lower layer of cork may be provided. However, the bottom layer may also basically consist of a nonwoven material, which is not solidified in accordance with the invention, however. Incidentally, it is understood that the lower layer may also be multi-layered, if required for certain applications.

Moreover, the present invention relates to a method for producing a panel for a floor, wall or ceiling covering or for a furniture component, preferably a floor covering, wall covering or ceiling panel or a furniture board, wherein the plate is a flat support plate and one on the support plate having applied upper layer.

As has already been stated above, plate production in the prior art takes place in such a way that the carrier plates are produced from a wood material at considerable expense.

The invention now goes a different way, wherein for the production of the support plate, a consolidated, needled nonwoven fabric is produced. The advantages resulting from the use of the consolidated fibrous web for the carrier plate are expressly referred to.

In the invention, the above-described mechanical, chemical and / or thermal solidification of the nonwoven fabric in connection with the production of the carrier plate can be realized both by a continuous and by a discontinuous process. In this case, the continuous production preferably takes place on a rolling device in which the compaction can be carried out by at least one pair of rollers with a top and a bottom roller. It is understood that the rolling device can also have a plurality of further rollers or further roller pairs following the first pair of rollers. In the discontinuous production, the so-called Kurztaktverpressung offers, in which a lower and / or an upper pressing part are provided. Preferably, the solidification of the nonwoven mats by means of (double) belt presses with preheating for heating or for partial melting of the fiber material.

As a result of using either the continuous or the batch process to solidify the nonwoven fabric, a rectangular sheet having a defined edge length, width and height results. The height of the nonwoven fabric and the selected pressing pressure control the specific gravity of the plate.

Regardless of the manufacturing process, it is such that the solidification device, ie either the rolling device or the short-cycle press, performs the compaction or compaction of the nonwoven fabric in the manner according to the invention via corresponding pressure and / or corresponding temperatures. Accordingly, the respective pressing device is provided with corresponding pressing cylinders and / or heating devices.

In order to achieve a cost-effective production of the plate according to the invention, it makes sense to produce the plate from a base plate which is several times larger than the plate itself. The base plate is after its production, that is, after the solidification of the non-woven fabric according to the invention, divided into a plurality of individual plates. Accordingly, the size of the baseplate is approximately equal to a multiple of the dimensions of a single plate.

Incidentally, in connection with the method according to the invention, it has been found that it is possible to press the tongue and groove joint at least in regions with the aid of the pressing device. It is also possible that only a precontouring of the tongue and groove connection takes place in the pressing device. In this case, the tongue and groove connection can be realized from the outset when pressing the fiber fleece. In principle, however, it is also possible that already pre-pressed non-woven plates with or without locking contours are provided laterally with a corresponding (supplementary) locking contour by a further pressing operation (continuous in a continuous or discontinuous manner), the subsequently re-pressed area being substantially harder. The pre-contouring or, if necessary, subsequent pressing of the tongue and groove joint has the significant advantage that comparatively little material of the backing plate has to be milled away for the final contouring of the locking contour. This reduces the production costs in creating the locking contours considerably, which has a corresponding cost-effective.

It is understood that, of course, it is of course also possible to perform any contouring or Vorkonturierung when solidifying the fiber fleece, so produce a base plate in a continuous or discontinuous process that is profiled edge only after its final creation.

Incidentally, the method according to the invention has the advantage that it is possible, the aforementioned upper layer, which may also be multi-layered, and / or the aforementioned lower layer, which may also be multi-layered, when solidifying / pressing the nonwoven fabric directly with the Carrier layer to connect. In the batch process, this means that in the mold first the lower layer, then the not according to the invention solidified nonwoven fabric and then the upper layer, optionally with their individual layers, are inserted and then the entire layer package is pressed. On the one hand, "directly connecting" means, in the continuous process, that the respective upper or lower layer is fed directly to the first pair of rolls used for the compaction or consolidation of the nonwoven fabric. At the same time it is also possible that the closing of the upper and / or the lower layer also takes place shortly after the first pair of rollers, which is possible until the continuously produced base plate is separated.

In this way, decor carriers or fabrics for surface finishing can be realized even in the pressing process. The process is very dimensionally accurate and true to detail.

A pressing device for producing a plate of the aforementioned type may have an upper pressing part, a lower pressing part and a mold cavity.

At least one contouring means may be provided on the upper pressing part and / or on the lower pressing part for forming a groove-and-tongue connection formed at least in regions on the plate.

As has already been stated above, the pressing device may on the one hand be a short-cycle press for the discontinuous production or else a rolling device with at least one pair of rolls for the continuous production.

Both in the continuous and in the discontinuous pressing device is provided as contouring at least one profiling, for example in the form of corresponding projections, Praflausnehmungen and / or projecting into the mold cavity movable mandrel or slider. By the use of the aforementioned mandrel, which is like a slider in the mold cavity and out of this movable, it is possible to provide an internal groove in compressing the nonwoven fabric for the production of the carrier layer in this.

Incidentally, at the upper and / or lower pressing part, regardless of whether the pressing device is a short-cycle press or a rolling device, such a contouring of the profiling may be provided which corresponds to the final groove and / or spring design of the Locking contour is at least substantially adapted.

In addition, the contouring means can be provided in the form of the profiling both in the longitudinal and in the transverse direction at the upper and / or lower pressing part, so that it is possible both in the continuous and in the discontinuous production, a pre-division of the base plate in the individual Make plates.

Other features, advantages and applications of the present invention will become apparent from the following description of exemplary embodiments with reference to the drawing and the drawing itself. In this case, all described and / or illustrated features alone or in any combination form the subject of the present invention, regardless of their Summary in the claims or their dependency.

Fig. 1

eine perspektivische schematische Darstellung einer erfindungsgemäßen Platte,

Fig. 2

eine perspektivische schematische Darstellung einer Möbelbauteilplatte,

Fig. 3

eine schematische Schnittdarstellung eines Teils einer Ausführungsform einer erfindungsgemäßen Platte,

Fig. 4

eine der Fig. 3 entsprechende Ansicht einer weiteren Ausführungsform einer erfindungsgemäßen Platte,

Fig. 5

eine der Fig. 4 entsprechende Ansicht einer weiteren Ausführungsform einer erfindungsgemäßen Platte,

Fig. 6

eine der Fig. 5 entsprechende Ansicht einer weiteren Ausführungsform einer erfindungsgemäßen Platte,

Fig. 7

eine schematische Darstellung eines Teils einer Ausführungsform einer erfindungsgemäßen Trägerplatte,

Fig. 8

eine der Fig. 7 entsprechende Ansicht einer weiteren Ausführungsform einer erfindungsgemäßen Trägerplatte,

Fig. 9

eine schematische Darstellung einer diskontinuierlichen Presseinrichtung vor dem Verpressen,

Fig. 10

eine der Fig. 9 entsprechende Ansicht der Presseinrichtung aus Fig. 9 während des Pressvorgangs,

Fig. 11

eine der Fig. 10 entsprechende Ansicht der Presseinrichtung aus Fig. 9 nach Beendigung des Pressvorgangs,

Fig. 12

eine Draufsicht auf das untere Pressteil einer Presseinrichtung,

Fig. 13

eine schematische Seitenschnittansicht einer kontinuierlichen Presseinrichtung während des Verfestigungsvorgangs,

Fig. 14

eine schematische Schnittdarstellung einer Trägerplatte aus dem verfestigten Faservlies,

Fig. 15

eine an den Randkanten profilierte Trägerplatte in schematischer Schnittdarstellung.

Fig. 16

eine Vorderansicht der Presseinrichtung aus Fig. 13,

Fig. 17

eine der Fig. 16 entsprechende Darstellung einer anderen Ausführungsform einer kontinuierlichen Presseinrichtung und

Fig. 18

eine Seitenansicht der Presseinrichtung aus Fig. 17 in schematischer Darstellung.

It shows

Fig. 1

a perspective schematic representation of a plate according to the invention,

Fig. 2

a perspective schematic representation of a furniture component plate,

Fig. 3

a schematic sectional view of a portion of an embodiment of a plate according to the invention,

Fig. 4

one of the Fig. 3 corresponding view of another embodiment of a plate according to the invention,

Fig. 5

one of the Fig. 4 corresponding view of another embodiment of a plate according to the invention,

Fig. 6

one of the Fig. 5 corresponding view of another embodiment of a plate according to the invention,

Fig. 7

a schematic representation of part of an embodiment of a carrier plate according to the invention,

Fig. 8

one of the Fig. 7 corresponding view of a further embodiment of a carrier plate according to the invention,

Fig. 9

a schematic representation of a discontinuous pressing device before pressing,

Fig. 10

one of the Fig. 9 corresponding view of the pressing device Fig. 9 during the pressing process,

Fig. 11

one of the Fig. 10 corresponding view of the pressing device Fig. 9 after completion of the pressing process,

Fig. 12

a top view of the lower pressing part of a pressing device,

Fig. 13

a schematic side sectional view of a continuous pressing device during the solidification process,

Fig. 14

a schematic sectional view of a carrier plate from the solidified nonwoven fabric,

Fig. 15

a profiled on the marginal edges carrier plate in a schematic sectional view.

Fig. 16

a front view of the pressing device Fig. 13 .

Fig. 17

one of the Fig. 16 corresponding representation of another embodiment of a continuous pressing device and

Fig. 18

a side view of the pressing device Fig. 17 in a schematic representation.

In Fig. 1 a plate 1 is shown, which in the present case is a panel or a floorboard for a floor covering, not shown, which is composed of a plurality of interconnected plates 1. Ultimately, it is in the plate 1 to a Badenbelagsplatte. The plate 1 has a flat support plate 2, on the upper side and thus firmly connected to an upper layer 3 is applied.

In Fig. 2 a plate 1 is shown, which is a furniture component plate. Also in Fig. 2 shown plate 1 has a support plate 2 and an upper layer 3.

A difference between those in the Fig. 1 and 2 shown plates 1 is that the floor covering plate Fig. 1 wall side has a locking contour, while such a contour is not provided on the furniture component plate edge. The edges at the in Fig. 2 shown plate 1 extend at least substantially at right angles to the top or bottom of the plate body.

The at the plate 1 off Fig. 1 On the edge provided locking contours have on one longitudinal side of a protruding spring 4 and on the opposite longitudinal side to a corresponding complementary groove 5. Furthermore, located on the one short side of the otherwise rectangular plate 1 also a spring 4, while on the opposite short side, a corresponding, complementary groove 5 is provided. The tongue and groove connection on the longitudinal and short sides, which is also called bung connection or bung can be basically identical. In the case of a click connection, however, they are designed differently.

The spring 4 and the groove 5 are presently provided for forming a so-called click connection with the result that the spring 4 can be engaged in the groove 5 of an adjacent plate during installation. In practice, the installation is usually carried out by obliquely applying the plate to be laid 1 to an already laid plate 1. This results in a preliminary engagement of the spring 4 in the groove 5. Subsequently, the plate to be laid is swung down, so that the Lock over the click connection results. At the same time there is a connection to the short sides after the plate to be laid 1 has been pushed to already laid plates 1.

It is now provided that the plate 1, regardless of whether it is a floor covering plate, a furniture component plate or a wall covering or ceiling panel plate, that the support plate 2 made of a bonded nonwoven fabric which is needled. In the illustrated embodiment, the nonwoven fabric at least predominantly natural fibers. In addition, the nonwoven fabric is impregnated with a binder. In this case, the weight fraction of the binder based on the weight fraction of the nonwoven fabric is about 1: 3. In the specific embodiment shown, the consolidated nonwoven fabric has a density in the range of 760 kg / m ³ , while it is also possible to use support plates 2 with a sufficient strength, which have a much lower density. Thus, in another alternative embodiment, a density in the range of 410 kg / m ^{3 is} provided. Incidentally, the material of the carrier plate 2 according to the invention can be described by the fact that the degree of compaction of the unconsolidated nonwoven fabric for the inventively solidified nonwoven fabric is in the range of 4.7.

In the Fig. 3 to 6 Possible embodiments of the plate 1 according to the invention are shown.

In all the illustrated embodiments, on the one hand, an upper layer 3, which is multi-layered in all embodiments, and the rest, a lower layer 6 is provided. In this case, the lower layer 6 at the in the Fig. 3 and 4 embodiment shown in one layer, while in the in the FIGS. 5 and 6 illustrated embodiments is formed in two layers.

Of course, it is understood that in all illustrated embodiments it is also possible to provide a larger or smaller number of layers in the upper layer 3 or the lower layer 6.

At the in Fig. 3 In the embodiment shown, the upper layer 3 has an outer layer 3a, which may be a vinyl and / or PUR and / or PP wear layer. Below the outer layer 3a is another layer 3b, which is a printed decorative paper. It is not shown that the further layer 3b is connected to the carrier plate 2 via an adhesive layer. Otherwise, an adhesive layer may also be provided between the further layer 3b and the outer layer 3a.

Instead of forming the further layer 3b as decorative paper, the further layer 3b may also be a printed vinyl carrier. If necessary, then the aforementioned not shown adhesive layers are provided.

In principle, it is also possible for the outer layer 3a to be designed as a corundum overlay under which there is a printed decorative paper layer which is impregnated, that is to say a resin. The connection to the carrier plate 2 then takes place via the resin of the further layer 3b.

Alternatively, it is also possible for a lacquer / corundum layer to be provided on the upper side as the outer layer 3a, which is applied to an underlying paper or vinyl carrier layer.

At the in Fig. 4 1, the outer layer 3a is applied to a further layer 3b designed as a protective overlay, to which a further layer 3c adjoins. In the illustrated exemplary embodiment, the layer 3b may be a protective overlay which is applied to a resinated, printed decorative paper layer as a further layer 3c.

In principle, it is also possible that the outer layer 3a is a structured lacquer layer, while the further layer 3c may be a printable nonwoven, that is solidified or not solidified. On the nonwoven layer as a further layer 3c then a digital printing is applied as a further layer 3b. Instead of the printable nonwoven as a further layer 3 c, it is also possible to provide a print overlay, for example in the form of a primer.

It should be noted that the individual layers shown are always shown with omission of any necessary adhesive layers. The adhesive layers are not to be understood as sub-layers within the meaning of the invention.

The in the 4 and 5 illustrated embodiments correspond to those in the 3 and 4 illustrated embodiments, at least as far as the upper layer 3 is concerned. One difference is that in the embodiments of the 3 and 4 the lower layer 6 is formed in a single layer, while in the FIGS. 5 and 6 is formed in two layers.

In the single-layer embodiment, a counter-stretch of cork is provided as the lower layer 6, for example. In the two-layered embodiment, a nonwoven layer can be provided in addition to the cork layer, which then is a nonwoven fabric not consolidated in accordance with the invention. The order of arrangement of the cork layer and the fiber fleece layer is arbitrary. In principle, a paper layer could also be provided in return for itself or in conjunction with one or both aforementioned layers.

in the FIGS. 7 and 8 in each case a part of a carrier plate 2 is shown schematically. At the in Fig. 7 In the illustrated embodiment, the carrier plate 2 is two-layered and has an upper layer 2a and a lower layer 2b. In the illustrated embodiment, each is the same nonwoven fabric material, wherein the upper layer 2a is more compressed than the lower layer 2b. The lower layer 2b is thus softer than the upper layer 2a. In the Fig. 7 illustrated embodiment is particularly suitable when a soft ride is to be generated. In this case, the upper layer 2a then provides a pressure distribution over the surface of the plate 1, while the layer 2b due to their better compressibility and lower hardness provides for damping during running / walking.

At the in Fig. 8 illustrated embodiment, the properties of the support plate 2 are made Fig. 7 extended by the properties of another layer 2c. However, other dimensions have been deliberately used. The layer 2c has a high degree of compaction and a high thickness. This is realized because the layer 2e is used to form the locking contour. Accordingly, the thickness of the layer 2c is larger than the maximum height of the groove 5, so that the groove 5 can be formed in the layer 2c.

In the Fig. 9 to 11 schematically a part of a pressing device 7 is shown. The pressing device 7 has an upper pressing part 8 and a lower pressing part 9. Between the upper pressing part 8 and the lower pressing part 9 is a mold cavity 10. In the in the Fig. 9 to 11 shown pressing device 7 is a so-called short-cycle press, which operates discontinuously. It is provided that 9 contouring means are provided for forming an at least partially formed on the plate 1 tongue and groove connection both on the upper pressing part 8 and on the lower pressing part. Specifically, it is in the illustrated embodiment so that a profiling 11 is provided on the upper pressing part 8, which images the upper region or the upper contour of the spring 4. At the lower pressing part 9 is also a profiling 12, which on the one hand part of the spring 4 and on the other hand, a part of the groove 5 images. Furthermore, located on the lower pressing part 9 is a movable mandrel 13, the tip of which is displaceable up to the mold cavity 10. The tip of the mandrel 13 is profiled so that it corresponds to the shape of the front end of the groove 5.

Incidentally, goes from the Fig. 9 to 11 the procedure in the batch production of a support plate 2 forth. First, a mat-shaped non-woven fabric material is inserted as a starting or base material in the mold cavity 10 of the lower pressing part 9. Subsequently, the upper pressing part 8 is moved down. It shows the Fig. 9 only an intermediate state. The downward movement of the upper pressing part 8 takes place until the two pressing parts 8, 9 lie on one another, as shown in FIG Fig. 10 is shown. The nonwoven material is compacted during compression. The binder in the nonwoven material reacts under the influence of pressure and heat and solidifies the nonwoven material in the compressed state. In the illustrated embodiment, a degree of compaction results between 4: 1 and 5: 1. After a predetermined pressing time, the upper pressing part 8 is moved upward, as in Fig. 11 is shown. simultaneously the mandrel 13 is retracted so far that its tip no longer or only slightly protrudes into the mold cavity 10. Subsequently, the solidified support plate 2 of the pressing device 7 or the mold cavity 10 can be removed.

It should also be pointed out that, instead of a movable mandrel 13, a mandrel projecting permanently into the mold cavity 10 could in principle also be provided. In this case, the solidified support plate would have to be removed obliquely from the mold cavity 10 or the pressing device 7.

Furthermore, it should be noted that instead of in the Fig. 9 to 11 embodiment shown in the pressing device 7 not only a support plate 2, but also a plate 1 with the upper layer 3 and / or the lower layer 6 can be produced. If both an upper layer 3 and a lower layer 6 are provided, first the lower layer 6 is inserted, on which then the not yet compressed mat made of nonwoven fabric is placed. In turn, the upper layer 3 is placed on this. The compression of the upper and / or the lower layer 3, 6 with nonwoven material, which subsequently forms the carrier plate 2, then takes place during the compaction in the in Fig. 10 illustrated state.

Incidentally, it should be pointed out that in principle it is also possible, instead of just a single plate 1 or carrier plate 2, to produce a base plate which is divided into a plurality of individual plates 1 or carrier plates 2 after the fibrous web has solidified.

In Fig. 12 is a plan view of a lower pressing part 9 of a pressing device 7 is shown, with which a base plate with 16 individual plates 1 can be produced. The lower pressing part 9 has a series of contouring means in the form of profilings 14, which are longitudinal and transverse projections which ultimately predefine the rectangular plates 1. On the upper side, the profiles are at least partially adapted to the shape of the locking contour, that is, the spring 4 and / or the groove 5 of the plates 1. To the in Fig. 12 shown lower pressing part 9 corresponds to an unillustrated upper pressing part, the distribution of the division of the in Fig. 12 shown lower pressing part 9 corresponds, the profiling provided there However, not necessarily correspond to the profilings on the opposite pressing part, but are adapted to the top-side profiling of the spring 4.

Incidentally, it is understood that the illustrated embodiment of the lower pressing part 9 is only an example. Basically, the lower pressing part 9 may have any number and shape of shelves for plates 1.

In Fig. 13 schematically a continuous working pressing device 7 is shown. This has as upper and lower pressing part 8, 9 in each case a roller, which in each case has a profiling 14 in the present case. However, it should be noted that the profiling 14, which represents the shape of a circumferential projection with an on-demand precontouring in adaptation to the profile of the tongue and groove joint, can basically also be omitted, so that only smooth, cylindrical rollers are used.

From the Fig. 13 also schematically shows the type of solidification. The pressing device 7 and the rollers is supplied with a binder impregnated with a thermoplastic fibers or non-woven material which is compacted for solidification. Here, too, a solidification takes place under a predetermined pressure and a predetermined temperature, with a degree of compaction of between 4: 1 and 5: 1 also being achieved here.

In Fig. 14 is the after the procedure off Fig. 13 produced carrier plate 2 shown schematically, which has been separated after manufacture by the pressing device 7 of the produced strand of material. It is understood that according to the method Fig. 13 individual support plates 2 but also base plates, which are then divided into individual plates 1, can be produced. Incidentally, it is also possible in the continuous process, not only to produce the support plate 2 via the formed as a rolling device pressing device 7, but also the plate 1 as such. In this case, the upper layer 3 and / or the lower layer 6 then passes directly to the pair of rollers 8, 9, or else the individual layers 3, 6 are fed in after the pair of rollers and before separation of the base plate / plate 1 / carrier plate 2.

While the in Fig. 14 shown carrier plate 2 can be used in principle as a furniture component, which is then provided on the upper side with the upper layer 3 and the lower side with the lower layer 6 and can also be provided on the edge with corresponding layers, is in Fig. 15 a carrier plate 2 is shown, which is processed on the edge side and are provided on the corresponding locking contours via a spring 4 and a groove 5. Subsequently, the upper layer 3 and, on the underside, the lower layer 6 can then be provided on the upper side of the carrier plate 2. At the in Fig. 14 illustrated embodiment, which is particularly suitable as a furniture component plate, can be provided that a paint coating is provided as a layer on the top and bottom sides and edge edge side.

In Fig. 16 is a front view of the pressing device 7 from Fig. 13 shown. Visible are the two outer profiles 14 and the intermediate central profiling 14 on the rollers. Although this is not shown in detail, the profiles 14 are not V-shaped at their ends, but at least partially correspond to the contouring or the profile of the tongue and groove joint on the top and bottom of the plate. 1

The embodiment according to Fig. 17 is different from the one in Fig. 16 in that 14 additional transverse profiles 15 are provided on the formed as rollers pressed parts 8, 9 in addition to the longitudinal direction in the direction of rotation profilings 14, which ultimately define the plates 1 or support plates 2 of a base plate to be produced. Also, the transverse profiles 15 are adapted at least partially on its upper side to the profile or the contour of the locking contour of the plate 1.

Fig. 18 shows a transverse view of the pressing device 7 Fig. 17 ,

REFERENCE LIST;

1

plate

2

support plate

2a

upper layer

2 B

another layer

2c

another layer

3

upper layer

3a

outer layer

3b

another layer

3c

another layer

4

feather

5

groove

6

Lower class

7

presser

8th

upper pressed part

9

lower pressing part

10

mold cavity

11

profiling

12

profiling

13

mandrel

14

profiling

15

profiling

Claims (9)

1. A panel (1) for a floor, wall or ceiling covering or for a furniture component, preferably a floor covering, wall cladding or ceiling cladding panel or a furniture component panel, comprising a planar substrate panel (2) and an upper layer (3) applied to the substrate panel (2),
   characterised in that
   the substrate panel (2) is produced by bonding a needled non-woven fabric or that the substrate panel (2) comprises at least one substrate layer consisting of a bonded needled non-woven fabric, wherein the density of the bonded non-woven fabric is between 400 kg/m³ and 1000 kg/m³ and the degree of compaction of the unbonded non-woven fabric compared with the bonded non-woven fabric is between 10:1 and 2:1, and that a lower layer (6) applied to the underside of the substrate layer is provided.
2. The panel according to claim 1, characterised in that the non-woven fabric is made of natural polymer fibres and/or synthetic polymer fibres and/or recycled fibres and that the non-woven fabric is mechanically and thermally bonded.
3. The panel according to claim 1 or 2, characterised in that the non-woven fabric is impregnated with binder and/or comprises thermoplastic polymer fibres, and that the substrate panel (2) preferably has a larger proportion of non-woven fabric material and a smaller proportion of binder and/or thermoplastic polymer fibres.
4. The panel according to any one of the preceding claims, characterised in that the material of the substrate panel (2) has a density of between 400 kg/m³ and 900 kg/m³ and/or that the weight per unit area of the substrate panel (2) is between 500 and 1500 g/m² per mm thickness.
5. The panel according to any one of the preceding claims, characterised in that the substrate panel (2) has a tongue-and-groove contour around its edge and that the substrate panel (2) is bonded to a greater extent in the region of the tongue-and-groove contour than outside the region of the tongue-and-groove contour.
6. The panel according to any one of the preceding claims, characterised in that the substrate panel (2) is multi-layer and that at least two layers of the substrate panel (2) have a different degree of compaction and/or of bonding.
7. Method for producing a panel (1) according to any one of the preceding claims for a floor, wall or ceiling covering or for a furniture component, preferably a floor covering, wall cladding or ceiling cladding panel or a furniture component panel, the panel (1) comprising a planar substrate panel (2) and an upper layer (3) applied to the substrate layer (2),
   characterised in that
   the substrate panel (2) is made from a needled non-woven fabric by bonding by means of a pressing device (7), wherein the density of the bonded non-woven fabric being between 400 kg/m³ and 1000 kg/m³ and the degree of compaction of the unbonded non-woven fabric compared with the bonded non-woven fabric being between 10:1 and 2:1.
8. Method according to claim 7, characterised in that a tongue-and-groove connection is pressed on in the pressure device (7) at least in some regions and/or that the panel (1) or substrate panel (2) is profiled around the edge in order to produce the tongue-and-groove contour.
9. Method according to claim 7 or 8, characterised in that the substrate layer (2) is connected to the upper layer (3) and/or to the lower layer (6) when the non-woven fabric is bonded.

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