DE3215684C2 - - Google Patents

Description

The invention relates to a method for manufacturing of decorative plates.

Decorative covering materials are different in many which versions are available and can, for example made of plastic, natural materials or combinations thereof consist. The material can be smooth or profiled Have wear surface, the latter Alterna tive from both practical and aesthetic Reasons is preferred in most cases. Professional The material has a multi-dimensional, contrast rich appearance, which, however, only through a flawless Synchronization of sample image and relief is available. A common surface embossing that the plastic surface is imposed and not with the existing Print pattern matches, this effect can not mention.  

The production of a shaped object with profiled surface is in DE-OS 19 18 418 described. As part of this process, a mixture made from shredded pulp and plastic in one mold Relief shape fused and then covered with cellulose containing plastic films (impregnated with resin Cotton wool) again formed in a press. The shape preferably consists of tool steel with a reverse grain, which can be found in it by pouring or Edit is formed.

For the production of wall and floor coverings are used Imitation wood made of plastic for several years excellent cork imitations with a relief surface, as well as all pure natural substances. Covering materials made from a combination of natural material and plastic in the form of a covering there are relatively thick plastic film, however only available with a smooth wear surface, as there is no Knows the process  through which a thick wear layer made of plastic can be attached to cork, for example, without the relief is leveled at the same time.

For a long time, smooth cork floor tiles made from a wear layer of art fabric, a decorative layer, an elastic layer and an underclass. The wear layer be is preferably made from calendered or coated Plastisol made of transparent, plasticized PVC with good Wear resistance and stain resistance. The elasticity layer consists of one by rotating or splitting Cork granulate blocks made sheets. That bow is pre-laminated with a thin, decorative cork veneer. The lower class serves as a mechanical voltage equalizer, and this layer or another counter layer to the wear layer complicates sinking of the plates and delays Moisture diffusion from the sub-floor. For the last one the layer mentioned, plasticized PVC film is used, the same strength module as the wear layer or has a higher one. In the finished floor construction is a balance of forces, and the Flatness of the plates is ensured.

Cork is out in the present context drawn material, but due to its extraordinary porosity and its large air content in the Manufacture of plates has significant difficulties rode. As a natural product, cork is also numerous rich defects, which are in the form of larger ones or smaller cavities or depressions make that are not accepted in the finished plate can. This means strict selection and costly Rejects in production. Especially thin cork Veneer panels with low compression are mostly full of holes that need to be filled out before the film covering can be applied.  

The wear layer is usually through Press glue connected to the underlying layer. Attempts have also been made to keep cork tracks in continuous To produce processes with painting and roller glue, but without much success.

In summary it can be said that a natural product in combination with a wear layer made of plastic film only in the form of a cork sheet with a smooth covering film layer occurs.

The invention has for its object by a new manufacturing process the production of both smooth as well as profiled plates and sheets of this type possible, related to flooring and wallcovering suitable for purposes and thanks to the small rejects become cheaper than the previously known products.

The solution to this problem is given in the patent specified measures and means achieved.

The method according to the invention is characterized in primarily from the fact that a completely new type of Backing layer is used which is made of granulated cell material in a matrix made of meltable plastic consists. Is the pulp material cork, and has the bottom layer thickness of about 2 mm, the particles may Size should not exceed 2 mm and should preferably be used less than 1.5 mm. Since one in the manufacture of the plate or the web the thin decorative layer on this base attaches and the layers at such a temperature pressed that the plastic hardens / melts, the Plastic mass with the cork filling in the existing opening rise and deepen the decorative layer and fill this out, which gives the decorative layer a smooth top area and a perfect appearance. The filling measure material can be given the desired color, for example a shade that more or less resembles the dominant color tone joins the decorative layer or stands out from it.

The wear layer, which usually consists of a  pre-coated 0.5 mm plasticized PVC film is applied on the decorative layer before this is combined with the base layer, d. H. all three layers are working in one and the same connected to each other. So when pressing, too the wear layer melted so that it was the decor layer adheres well. The wear layer can also from another material, for example from foils Plastisol, various varnishes or polyurethane exist.

After the product for a predetermined time has been pressed, it is delivered to a cold press, in which it cooled and at the same time a higher press exposed to pressure, expediently about twice as high as in the hot press. The one from the cold press removed plate or sheet has the above, advantageous appearance and a completely smooth wear surface and is as such as floor and wall covering usable.

To make a plate or sheet with relief, a natural substance is required, the so-called elastic Has memory. One such substance is cork. The cork with its special cell system is pressed by pressing seals but partially springs back with a time delay, whom he is relieved of. Since in the above case the load is only eliminated after the plastic has cooled the tension of the cork is blocked, which is why the Plate or sheet that receives the smooth wear layer side. If, however, the plate or web has cooled down after one free heating (i.e. heating that does not is influenced by the press plate or the like) on a Exposed to temperature that is higher than the exp temperature of the plastic, the tension relaxes condition of the cork, and the cork takes it again Shape that he had before pressing. One uses plasticized PVC, is a reheating temperature suitable from 70-150 ° C. After reheating, leave Cool the plate or web freely as well. This change of state  leads to a profiled wear layer side of a very advantageous appearance, since the profiling of the Wear layer controlled by the material of the decorative layer pattern and relief are perfectly synchronized will.

As indicated above, cork is going to be extremely Partially proven for the manufacture of a natural product plate with relief, the decorative appearance of the Structure and composition of the thin used Layer or veneer. The layer will by splitting a block of cork conglomerate into thin sheets that manufactured a number of different growth zones with varying, mutual orientation and compresses have sensitivity. The different zones have under different elasticity and recoverability where by forming relief from simple nodules to one accomplished art of nature may vary. Although cork is currently the most suitable material other pulp conceivable that this for the relief have elastic memory required for education or who can be given this memory.

A particular advantage of the Ver driving is that no pulp is lost, since all rejects are turned into granules. Of course, this means further cost savings nisse beyond those achieved by that it is not necessary to fill the decorative layer, and in that the quantities of unusable products are small will.

A plate made in this way with a Base layer made of granulated pulp in one Die made of meltable plastic, a thin decor layer on the base layer and wear layer of plastic film made of meltable plastic, which the latter by that made after hot pressing Cold press a smooth top or by renewed Heat in the free state after cold pressing one  Relief area has not only been extremely decorative tiv, but also extremely advantageous in use, because it is wear-resistant and thanks to its elasticity and insulating ability when walking feels extremely pleasant.

The invention is based on the following embodiment example explained in more detail.

On a calendered, 2 mm thick bottom layer made of plasticized PVC and cork granulate with one part size of up to about 1.5 mm became 1 mm thick Cork veneer attached, which has a 0.5 mm thick wear layered film made of plasticized PVC was applied. The Material was placed in a press with spacers form with release paper on both sides placed. The pressing was carried out in a hot press (180 ° C) under gradually increasing pressure of up to 196.133 kPa executed during 5 min. The form and its content was then put into a cold press while warm brings, where the pressure from 196.133 kPa to 490.3325 kPa was increased for 5 min, after which the cold product was removed from the mold. The product was now completely flat, but with the subsequent heating to 130 ° C for 2 min in the surface a relief, the appearance of which be used structure of the cork veneer was determined.

Claims (7)

1. A method for producing decorative panels, characterized in that a pulp is granulated, after which the granules are mixed with meltable plastic and a mat is made from the mixture that pulp of the same or different type is cut into thin slices, which in the present state with through openings and depressions are made on the mat thus produced, that a film made of meltable plastic is applied to the thin pulp disks, and that the laminate thus obtained is pressed into the openings and depressions of the disks with heating to melt the plastics and press up the mat material , after which the pressed plate is cooled. 2. The method according to claim 1, characterized in that that cork is used as the pulp to be granulated.   3. The method according to any one of claims 1 and 2, characterized characterized in that cooling in a cold press is made in the plate a higher pressure than exposed to hot pressing. 4. The method according to any one of claims 1 to 3, characterized in that after cooling a plate free heating and cooling in order to form the relief Plastic film is exposed. 5. The method according to any one of claims 1 to 4, characterized in that a thin cork Natural material layer is used. 6. The method according to any one of claims 1 to 4, characterized characterized in that an existing wooden granulating natural product is used. 7. The method according to any one of the preceding claims, characterized in that plastics from plasticized PVC can be used.