DE10344755A1 - Floor plate comprises a carrier layer consisting of particulate polypropylene foam, and a top layer, in particular, of natural stone joined to the carrier layer so that it stands back from its edge at least on two sides - Google Patents

Abstract

The floor plate comprises a carrier layer (1) consisting of particulate polypropylene foam with a particle size from 1 to 15 mm, and a top layer (2), in particular, of natural stone joined to the carrier layer so that it stands back from the edge of the carrier layer at least on two sides. An independent claim is also included for a floor constructed of the proposed floor plates.

Description

The The invention relates to a floor plate with a carrier layer and a surface layer, in particular of natural stone.

The Invention is preferred for lining the floor in vehicles However, of course, such as motorhomes or caravans used in houses and on existing floors be used. Also a use for coverings of all kinds such as for example on walls, Floors, ceilings and facades is possible. Especially the invention is used when under the floor underfloor heating should be attached.

The Use of natural stone for Floor panels of vehicles, in particular motorhomes and caravans, would be because Its appearance is very popular, but problematic as it is mechanical Loads during use, especially during the ride, not withstand, but even with slight twisting breaks or itself when mounted on a carrier layer of this replaces and / or breaks. Can be reduced the danger of breaking through a corresponding, massive thickness of natural stone, which, however, has an enormous weight. Versus the danger of replacement does not help this approach.

By the bonding of thin ones Layers of natural stone with lighter material can add weight same optical effect can be significantly reduced if the lighter Material sufficient resilience and torsional security the construction ensures.

From the DE 42 18 481 A1 For example, there is known a method for producing a composite panel with external stone panels, in which the back of the tile receives an epoxy layer which may include a reinforcement and with which the composite panel may be attached to surfaces.

adversely on the composite panels produced in this process is that they do not have a high stability lending element while the massive shape of the Epoxy resin layer, especially with a metal reinforcement, a high weight the plates result.

In the DE 195 47 123 A1 is a composite panel made of natural stone and wood described in which a natural stone layer is connected by means of a fiber-reinforced adhesive layer with a support plate made of wood.

adversely because of that is the massive backing plate made of wood, although a high stability the construction, for it but also causes a very high total weight. There is also wood an expensive, high quality material.

Out DE 25 08 628 is a floor element known, consisting of a chipboard, on the underside of a continuous plate of foamed plastic is glued, which has parallel, groove-shaped recesses on the upper and lower bearing surface.

Of the Disadvantages of this floor element is the reduced by the recesses power transmission especially for horizontal, but also vertical forces.

The DE 197 26 502 C1 shows a plate-shaped semi-finished product, which is composed of a natural stone layer and a stone imitation layer, wherein the imitation stone layer consists of a foamed mixture of polyurethane, silica flour particles and additives such as flame retardants and color pigments.

At This semifinished product is disadvantageous in that the foamed imitation stone layer a low force and pressure stability results. In addition, the composition is complex and thus cost-inefficient.

By the DE 295 08 697 U1 describes a large-scale thin slate lightweight panel, which consists of a slate layer and a lightweight carrier material bonded thereto, wherein the lightweight carrier material may be a hollow body, a honeycomb composite panel or a grate and may consist of rigid foam, aluminum or plastic, wherein the plastic is glass fiber reinforced, a Epoxy resin or a rigid foam can be.

adversely is that this construction when using a hollow body as Carrier material though easy, but not stable while a honeycomb core panel, although a significantly higher load capacity which, however, is not optimal, since none through the entire Plate continuous line of force is present. Besides that is the area, which can be used for bonding with the slate, in all variants of the carrier material small, so that a safe absorption of horizontal forces does not take place. Due to the small thickness of the slate is also only a very low local pressure load possible.

At All the above arrangements is disadvantageous that they are not for Laying provided in connection with several similar arrangements are.

From the DE 195 08 318 C2 is a tile element with a carrier core body and a dar on arranged glaze surface element in which the carrier core body consists of foam and between the two parts a reinforcing fabric may be arranged, wherein the foam of Polymetacryllimit, phenol-formaldehyde resins, urea resins, PVC, polystyrene, phenolic resins or polyurethanes. The tile element can have a tile overhang on one side and a core overhang on the opposite side while leaving a gap in the usual joint width between the tiles.

all So far, arrangements are common that they are very tough regarding the accessibility are.

From the DE 100 05 737 C2 is known a combination of edge-impacting multilayer panels consisting of at least one pressure-sensitive core layer and two covering the core layer on both sides covering plates which are resistant to acting pressure, wherein the multilayer panels are joined together by an adhesive seam.

At This connection is disadvantageous in that the multilayer plates three layers, which increases costs and complicates manufacturing. For the Covering layers are only intended for PVC, aluminum or wood.

all previously mentioned arrangements is the particularly high sensitivity a surface layer across from a twist and the resulting damage or destruction the surface layer common.

Farther is not in any of the arrangements, the use of an underlying Underfloor heating makes sense possible, because they look very good insulating.

In the DE 101 38 848 A1 describes the coating of polypropylene-plastic foam with coating-unfriendly surfaces, in which on the plastic foam surface to be coated, a glue base made of a nonwoven fabric is applied.

it is disadvantageous that neither the use of natural stone nor the Laying provided in connection with several similar arrangements are. In addition, here is the particularly high sensitivity of the surface layer across from a twist and the resulting damage or destruction given the stone layer. A use with underfloor heating is not scheduled.

Of the Invention is based on the object, a light, against all external loads stable floor plate, which also in vehicles with the required torsional insensitivity can be used to form a floor, which also has underfloor heating can be used meaningfully and thereby have a natural stone surface can not be damaged by external torsional forces and specify such a ground.

According to the invention Task with an arrangement which the features specified in claim 1 contains and an arrangement having the features specified in claim 14 contains solved.

advantageous Embodiments are specified in the respective subclaims.

Advantageous on the arrangement according to the invention is that the production of the floorboard through the small number of two layers plus an optional tie layer is very simple, fast and inexpensive and that the surface layers in principle, be arbitrarily thin depending on local load requirements can, which, together with the lightweight construction of the carrier layer an extremely low Total weight results, especially if natural stone material for the surface layer is used.

Farther is the load capacity, in particular the torsional security, the floorboard and the entire floor by the properties of the carrier layer and the possible Connections between the carrier plates or between the surface layers very large.

there cheap prefabrication and storage in larger quantities, by the simple Workability possible be, the backing plates and also the assembled floorboards.

One further advantage of the floor panel according to the invention and the floor according to the invention are the good heat transfer properties, thereby she is very good for the use with underfloor heating are suitable. In order to achieve even better heat transfer to the surface, in the carrier plates Recesses are provided. To a resulting, possibly loss of stability To avoid, carrier plates can with a higher one Density be used.

The Floor plate according to the invention is also temperature insensitive up to 150 ° C.

Furthermore, the elasticity of the carrier a pleasant, ergonomic walkability.

The Invention will be explained in more detail below with reference to an embodiment.

To demonstrate

1 a cross section of a floor panel according to the invention,

2a and 2 B an arrangement possibility of one and several floorboards according to the invention,

3a and 3b another possible arrangement of one and more inventive floor panels,

4 another arrangement possibility of several inventive floor panels to a floor,

5 a floor panel according to the invention with an additional coating between the two layers,

6 a cross section of a floor panel according to the invention with intermediate layers and

7 a section of a floor according to the invention.

In 1 is a floorboard according to the invention of a carrier layer 1 and a surface layer 2 shown schematically in cross section.

The carrier layer 1 consists of extruded, preferably open-cell polypropylene foam (EPP), preferably in a thickness of 4 mm, and is foamed with air, carbon dioxide or other blowing agents. He is elastic and very well thermally conductive through the open pores. By adding flame retardants, the flammable material can be adjusted to low flammability.

Of the PP foam is preferably used in a cut form, resulting in the open cells. Also the use of moldings made of PP foam is conceivable. For the production of the foam preferably foam particles of a size of 1 to 15 mm used.

The surface layer 2 can in principle consist of any material that is suitable for the particular intended use of the floorboard.

Prefers it is made of natural stone, such as marble, chosen, however For example, artificial stone, metal or glass are also conceivable.

The preparation of the floor plate is easiest by the surface layer 2 clamped behind and the polypropylene foam is foamed and thereby without further adhesive layer with the surface layer 2 combines.

In the carrier layer 1 are for example recesses 5 arranged, which is the transport of hot air from an underlying floor heating to the surface layer 2 even easier.

In the floorboard according to the invention is the surface layer 2 from the edge of the carrier layer 1 back, so that when laying several inventive floor panels between the surface layers 2 Put 4 available.

The surface layer 2 can, as in 2a represented, on all edges from the edge of the carrier layer 1 For example, in the case of rectangular plates, however, this is sufficient for two edges which are not opposite one another, such as, for example, in FIG 3a shown so that in the same direction laying several plates regularly at all panel joints joints 4 available. In the same sense, in this case, it is meant that the plates are placed together so that edges with receding surface layers 2 always have the same orientation and therefore always meet with not all-sided residue on edges at which surface layer 2 and carrier layer 1 finish flush. Examples show 2 B respectively 3b ,

The use of plates with differently arranged layers as in 4 is basically useful, but not mandatory, so that, for example, at the edges of floors, the surface layers 2 not at the edge or edges of the carrier layers 1 stand back, but for example only on the bottom surface facing edges, while the not lying on the edge of the bottom surface plates all-round receding surface layers 2 can have.

An improved adhesion with a reduced amount of adhesive results from a nonwoven, which is connected as an adhesive base with the carrier layer. In 5 is between carrier layer 1 and surface layer 2 such a coating 3 arranged.

In addition, the coating can 3 also contain CFRP strips as reinforcement. These are directly with the surface layer 2 connected and in the coating 3 or in the carrier layer 1 recessed grooves arranged. Instead of grooves, the entire thickness of the carrier layer can also be used 1 cutting slots may be provided. In this case, the carrier layer 1 in parts that lie between the slots to be connected to the surface layer.

Also without coating 3 with direct connection of carrier layer 1 and surface layer 2 can these reinforcing elements in the carrier layer 1 be arranged, also here preferably with the surface layer 2 connected.

For the purpose of more universal processing, it is possible initially only support plates 1 with coating 3 regardless of the final surface layer 2 can be produced and stored. On the coating 3 can cover a wide variety of surface layers 2 or other intermediate layers 6 or 7 then be applied later as needed.

The additional coating 3 can either be flush with the surface layer 2 complete and thus to the same extent as these from the edge of the carrier layer 1 stand back or it can be flush with the backing layer 1 to lock.

In 6 a floor panel according to the invention is shown, which is constructed of several layers, for example, to obtain a changed heat transfer behavior. On the carrier layer 1 are still two layers 7 , For example, cut polypropylene foam and the same thickness as the carrier layer 1 , arranged on which then the adhesive coating fleece 3 is applied. On this one is one with metal reinforcement 6 provided natural stone layer 2 attached.

7 shows the bonding of several inventive floor panels to a floor according to the invention. Here are the carrier layers 1 glued together elastically and the joints 4 between the surface layers 2 elastically filled, so that a movement and / or distortion of the plates relative to each other is possible without the joints 4 rupture or the surface layers 2 experience harmful pressure or tensile forces.

The carrier layers 1 do not necessarily have to be connected to each other. If they are connected, an elastic connection is expedient, but an inelastic connection is also possible because the carrier layers 1 in itself are already elastic.

The width of the joints 4 In this case, the arrangement of the layers as a function of the joint filling material preferably sets up such that the expected forces can be compensated without damage.

Because the surface layers 2 in relation to the entire soil each have only relatively small areas and also with other surface layers 2 are elastically connected, take the carrier layers 1 and their possible connections as well as the elastically filled joints 4 possible twisting forces on, while the surface layers 2 remain undamaged and continue to form a closed surface.

Appropriately, a heat insulation is mounted below the floor according to the invention and below an underlying floor heating. If closed-cell PP foam is used for the floor panels, this thermal insulation can be achieved with sufficient thickness of the support layer 1 omitted.

1

backing

2

surface layer

3

fleece

4

Gap

5

recesses

6

metal reinforcement

7

interlayer

Claims (16)

Floor plate with a carrier layer ( 1 ) and a surface layer ( 2 ), in particular of natural stone, characterized in that the carrier layer ( 1 ) of extruded foam of foam particles of a size of 1 to 15 mm made of polypropylene and the surface layer ( 2 ) with the carrier layer ( 1 ) and at least two sides of the edge of the carrier layer ( 1 ) stands behind. Floor panel according to claim 1, characterized in that the connection with the carrier layer ( 1 ) is formed by the adhesion of the polypropylene foam. Floor panel according to claim 1, characterized in that the connection with the carrier layer ( 1 ) by bonding with a coating ( 3 ) arises. Floor panel according to claim 3, characterized in that the coating ( 3 ) is a nonwoven. Floor panel according to one of the preceding claims, characterized in that on the underside of the surface layer ( 2 ) Reinforcements in the coating ( 3 ) or in the carrier layer ( 1 ) are arranged. floorboard according to claim 5, characterized in that the reinforcements CFRP strips are. Floor panel according to one of the preceding claims, characterized in that the surface layer ( 2 ) on all sides 0.2 to 2 mm from the edge of the carrier layer ( 1 ) stands behind. Floor panel according to one of the preceding claims, characterized in that the carrier layer ( 1 ) has a thickness of 3 to 40 mm. Floor panel according to one of the preceding claims, characterized in that the surface layer ( 2 ) has a thickness of 1 to 15 mm. Floor panel according to one of the preceding claims, characterized in that the polypropylene foam of the carrier layer ( 1 ) is foamed with air. floorboard according to one of the preceding claims, characterized the polypropylene foam has at least one cut surface. Floor panel according to one of the preceding claims, characterized in that between the support layer ( 1 ) and the surface layer ( 2 ) at least one further layer is arranged. Floor panel according to claim 12, characterized in that at least one of the further layers has a structure and / or a composition like the carrier layer ( 1 ) having. Floor composed of a plurality of multilayer plates, in particular of plates according to one of claims 1 to 11, characterized in that the carrier layers ( 1 ) of the abutting plates at the edges are elastically bonded together and the joints ( 4 ) between the surface layers ( 2 ) are filled with elastic material. Floor according to claim 14, characterized that he is used in a vehicle. Floor according to claim 15, characterized that the vehicle is an RV or caravan.