CN1922004A - Floor panel - Google Patents

Abstract

The invention relates to a floor panel (1, 2) comprising a carrier plate (3, 4) on which a use layer (5, 6) is applied, which use layer has a pattern that is decoratively divided into different pattern areas, wherein the decorative pattern is protected against wear by means of wear-resistant particles, and wherein the surface of the use layer has a relief-like structure comprising depressions and elevations, wherein the depressions overlap a defined pattern area and the elevations overlap other pattern areas of the decorative pattern, said decorative pattern being covered with a layer of transparent lacquer; the depressions of the relief-like structure are caused by a chemical which reacts with the lacquer; and wear-resistant particles are embedded in the paint layer.

Description

floor panels

technical field

The invention relates to a floor panel comprising a support plate on which a use layer is applied, the use layer having a pattern decoratively divided into different pattern areas, wherein the decorative pattern is achieved by means of wear-resistant particles To prevent abrasion, and the surface of the application layer has a relief-like structure comprising depressions and elevations, wherein the depressions overlap defined design areas and the elevations overlap other design areas of the decorative design.

Background technique

In order to imitate wood surfaces, ceramic surfaces or rock surfaces, so-called laminated boards are known from which floor panels are made. Laminates usually have a service layer consisting of at least two superimposed paper layers, which is placed on a support board made of wood. As the wood, medium-density or high-density fiberboard, particle board, or the like is used. In most cases, large-area panels are pressed and then divided into individual panels, which are further processed into floor panels. Floor panels are usually rectangular. One of the papers used is printed with a graphic pattern of the surface to be imitated. However, printed paper generally has low abrasion resistance and must therefore be protected against abrasion by means of a transparent paper with abrasion-resistant particles, a so-called cover layer. Powdered granules are used for this purpose, which consist, for example, of aluminum oxide, which is a raw material from which, among other substances, the frosting is made. A relief-like structure is punched out on this cover layer with an extrusion tool. The usage layer thus consists of a visual imitation layer and a tactile imitation layer of the surface. In other words, the surface feels as if it reproduces the pattern of the material it is intended to emulate.

Patterned paper is impregnated with a resin, such as phenolic resin or melamine resin or a hybrid form, after application of the pattern. The resin may contain, for example, additives for improving processability and fillers for reducing raw material costs. The overlay is likewise added with resin. These two layers of paper are then joined to each other and to the support plate by melting of the resin during hot pressing.

The use of resin-impregnated paper is problematic and expensive. There is a problem because the length and width of the paper on which the design is printed develops. The dimensions of the paper change after impregnation due to the wetting of the paper with the molten resin and the growth associated therewith. It depends on some influencing factors, such as air humidity, quality of paper, quality of resin, etc. After impregnation the surface structure must be imprinted on the resin paper with an extrusion tool. However, such surface structures often cannot be accurately superimposed on the engraving pattern due to paper size variability. Therefore, to process an impregnated paper it is necessary to divide into two steps. The first step must be to reduce the length and width of the decorative print and print it on paper with the prescribed reduced size. In the second step, the paper is wetted with resin and grown. At this time, the paper should match the size of the extrusion tool in the grown state. This method is inaccurate due to the variability of paper growth.

Furthermore, the use of resin-impregnated papers requires a so-called counter-tension, ie a layer of paper must be placed on the underside of the support plate in order to establish a balance with those papers forming the application layer on the upper side of the support plate. If there is no anti-tension force, severe deformation of the floor panel will occur after the paper layer and the support plate are hot-pressed.

The complexity of resin and paper processing increases the reject rate when producing impregnated decorative prints. Papers under or over the nominal size cannot be used in laminates because the design and embossing do not overlap.

Furthermore, the energy and equipment costs for pressing resin-containing paper and carrier boards are high, since high temperatures and heat must be introduced into the layers to be joined in order to melt the resin and thus join the layers to one another.

Another disadvantage is the placement of wear-resistant particles. Two alternatives are known for adding particles. Scenario 1: The particles are in the paper of the overlay. Particles are incorporated into the paper fibers during the production of the overlay paper. This cover paper is then impregnated with resin. Option 2: Overlay paper has no particles. Instead, the particles are mixed in the resin, but the overlay paper is only coated on one side with the resin/particle mixture, and the opposite side of the overlay is coated with resin without particles. For embossing relief-like structures, the particle-free resin-coated side of the cover paper faces the extrusion tool to prevent the surface of the extrusion tool from being abraded by hard particles.

The disadvantage of the two variants mentioned is that the surface of the relief-like structure consists of particle-free material up to a certain depth. This particle-free material wears out quickly when the floor panels are in use. Wear is only delayed when the layer in which the wear-resistant particles are distributed is exposed by abrasion. Of course, the relief-like structure of the surface has been destroyed by this time.

Contents of the invention

The object of the present invention is to create a floor panel which provides an exact overlapping of the decorative pattern area and the associated surface structure, wherein the floor panel provides a wear-resistant relief-like structured surface and can be produced easily and economically.

According to the invention, the measures taken for this purpose are that the decorative pattern is covered with a lacquer layer; that the depressions of the relief-like structure are produced by a chemical which reacts with the lacquer; and that wear-resistant particles are inserted into the lacquer layer.

The painted decorative pattern can be applied as a preform, eg on paper or film, and joined thereto for the production of laminates. For the connection, lower pressures and temperatures are sufficient than for the connection of resin-impregnated paper to wood panels. Since the floor panels do not need to be impregnated with resin, the pressing of the laminate or the rolling of the laminate can be simplified. Depending on the method of connection between the support plate and the preform, heating equipment can be completely dispensed with. Deformation of the floor panels is avoided due to the low heat input. The counter-pull can thus be eliminated. In addition, graphic designs can be printed without regard to dimensional shrinkage. As a result, the imitation of the reprinted surface is simplified, since both the reduction step and the subsequent enlargement step due to the paper enlargement when carrying out the printing can be dispensed with. Since stamping of the paper surface is eliminated, problems associated with positioning the design and the surface structure relative to each other do not occur and an exact superimposition of the design areas of the surface structure and the textured design is achieved. In this way, it is possible, for example, to feel tactilely imitated wood details on the embossed surface, and also to form the pattern exactly at the same location in a deeper layer. This pattern can be seen through the clear lacquer. Such tactile and visual impressions overlap each other harmoniously and accurately in place. In this way a better imitation of wood surfaces, ceramic surfaces, rock surfaces etc. is achieved.

The relief-like structure of the application layer is formed by the lacquer layer. The wear-resistant particles are distributed in the paint layer and reach the paint surface. Thus, there are no grain-free areas between the surface of the pattern pattern and the relief-like structure, which would wear away quickly. Therefore, the wear-resistant effect achieved by the wear-resistant particles is immediately produced when the floor surface is used. The described relief-like structured surface resists abrasive loads particularly well.

In short, the decorative pattern and the varnish layer are applied to the prefabricated decorative paper and the decorative paper is connected to the carrier plate in the finished state of the floor panel. Alternatively, a decorative film can also be provided instead of the decorative paper. The advantage of using a decorative film made of plastic is, for example, that it can be stretched. Due to this property it can be clad better and can be used, for example, as an edge-shaped three-dimensional covering.

The painted decorative paper is advantageously attached to the carrier plate with an adhesive. Any suitable physical bonding or chemically reactive adhesive can be used as the adhesive. It is also possible to use an adhesive, for example in the form of a double-sided film placed between the decorative paper and the carrier board. This adhesive can be coated on paper or film before extrusion.

Advantageously, the lacquered decorative paper forms an edge-part covering at least at two opposite edges of the carrier plate. The edges of the support plate are usually machined. Expose the wood fibers of the backing board wood. Dry wood can thus absorb small amounts of moisture and swell. By covering all or part of the processed edges, the intrusion of moisture into the wood is prevented. The application layer consisting of painted decorative paper is preferably applied after edge chamfering at the milled edges of the support plate. Here, the decorative paper sticks out from the edge of the cut corner to be layered. The decorative paper is then extruded and glued to the backing board. Decorative paper can be either cut to the required length or shortened to the required size after bonding.

Because the surface of the floor panels has a concave-convex structure, the edges where the two panels meet must not be congruently superimposed on each other. The edge height of a floor panel varies between the highest and lowest points of the surface relief-like structure. In other words, the edges of a floor panel run in irregular waves. This course occurs during the cutting process of the edge of the floor panel. This change in course of the edge corresponds to the profile of the relief-like structure in the plane in which the edge is processed.

In the assembled state, according to the prior art, a subregion with a deep edge of a floor panel may abut against a region with a higher edge of an adjacent panel. Consequently, the high edge regions protrude from the floor surface and are at risk of being damaged. They are easily damaged by impact. In order to prevent such damage, the support plate of the proposed floor panel, expediently on the side where the floor is used, has a chamfered edge on its outer edge. This prevents the edges from peeling off. Such edges are less sensitive, since a depression is formed in the joint region of adjacent floor panels, and the deeper edges are protected against impacts and wear.

In short, the two opposite chamfered edges of the carrier plate are covered with a self-adhesive decorative film layer. This has the advantage that, for example, on a carrier plate of rectangular shape, two opposite chamfered edges can be completely covered with the application layer. Covering the remaining two edges is complex in terms of processing technology, since the application layer has slightly more area in the region of each corner than is required for covering. Excess of the use layer must be cut off before or after each corner of the rectangular floor panel is clad.

Alternatively, the proposed edge protection by covering the floor panels can be achieved by adding a self-adhesive decorative film layer. This simplifies processing. For this purpose, the first edge must first be covered with the application layer. They are then machined at the ends, for example with a milling cutter, in order to remove the protruding parts of the application layer. This results in a regular surface to which the decorative film layer is applied.

For the sake of completeness it should also be mentioned that it is also possible to process decorative films which are not self-adhesive and have to be applied by means of other suitable adhesives. The decorative film does not have to contain abrasion-resistant particles, since the chamfered edges are indented below the finished floor surface and are thus subject to slight abrasion.

The cladding can extend beyond the edges of the chamfer to cover the edges of the floor panels. As a result, the processed edges of the floor panels still have a larger portion to protect against the ingress of moisture. Even if the edges of the support plate have a groove and tenon profile, pairs of opposing edges can be completely or partially covered with the application layer. The complete covering of the tenon profile is expensive. The cladding of the tenon profile up to or almost to the tenon and the cladding of the free ends of the groove walls on the groove profile are relatively simple in terms of production technology, since the application layer only has to be bent to the edge of the chamfer. Further bending, for example around the upper side of the tenon profile or into the groove of the groove profile, increases the technical costs.

The edges of the support plate can have form-locking interlocking profiles with undercuts, which prevent the floor panels from being pulled apart in a direction perpendicular to the interlocking profiles in the laid state in the plane of the floor panels. Likewise, the edges of the support plate can also have conventional groove and tenon profiles that must be glued together.

The covering is of particular importance for floors with a defined laying pattern, such as a herringbone pattern, which consists of wooden strips. To date, mainly floor panels have been produced which can have a pattern of strips, for example floor panels with the appearance of a ship's bottom. Laying patterns, such as a herringbone pattern, can be made without large floor panels because the direction of the seams between the panels interferes with the appearance of the herringbone pattern. Furthermore, the wooden strips at the edge of a floor panel are only part of the pattern. The strip sections patterned at the edges must be combined during laying by fitting precisely against the adjacent floor panels so that the two patterned strip sections complete one complete strip. Care must be taken here to have an exact pattern at the joints, in order to avoid a phase shift of the strip sections which would together form a strip.

One way of laying such a pattern consists in designing the individual wooden strips as small floor panels instead of a pattern of several wooden strips on one large floor panel. Each floor panel is in a single batten pattern. So laying patterns no longer have any patterns. Instead, the laying pattern is formed by means of individual imitation wooden strips, which are arranged in any desired pattern like the original wooden strips.

This measure of laying imitations of individual wooden strips increases the share of joints in the floor. Seams hitherto modeled as printed seams on large-area floor panels are now actual seams. Therefore, the smaller the floor panels, the more important it is to protect the processed edges of the floor panels. Due to the relatively high joint proportion of the small floor panels, more moisture can penetrate into the carrier plate during cleaning, for example, than a floor made of large-area panels. However, by covering the edges of the small floor panels as described above, it is possible to sufficiently prevent the seams from absorbing water.

A paper layer or a film layer can be placed on the underside of the carrier plate for waterproofing or as a measure for dampening footsteps. Said layer can be connected to the underside of the carrier plate in a point-like manner. An overall connection such as the connection of the tension-resistance layer to the support plate can be dispensed with.

Description of drawings

The invention illustrated by way of example in the drawings will be explained in more detail below with reference to the drawings. in:

FIG. 1 Detail of two interlocking floor panels with chamfered edges, wherein the upper side of the panels is provided with a painted application layer;

Figure 2 is a schematic diagram of the usage layer;

Figure 3 is a partial view of two interlocking floor panels with chamfered edges, wherein the upper side of the panels is provided with a painted application layer and a partial cladding of the interlocking profiles milled; and

FIG. 4 is a partial view of two interlocking floor panels without chamfered edges, wherein the upper side of the panels is provided with a painted application layer.

Detailed ways

FIG. 1 shows two interlocking floor panels 1 and 2 according to the invention. Each floor panel 1 or 2 has complementary interlocking profiles on opposite edges, so that the profile of one edge of the floor panel matches the profile of the opposite edge so that it is always possible A similar floor panel is fastened to the laid floor panel. The floor panel 1 therefore has a groove profile (not shown) on the edge facing away from the tongue profile 15 , while the floor panel 2 has a groove profile (not shown) opposite its groove surface 14 .

The two floor panels 1 and 2 have a carrier plate 3 or 4 on which a service floor 5 or 6 is arranged.

In order to illustrate the structure of the use layer 5 or 6, FIG. 2 schematically shows part of the use layer. Accordingly, the layer used is paper 7 which is printed with a decorative pattern 8 and which can be referred to as patterned decorative paper 7 . The pattern pattern 8 is divided into different pattern areas 9 and 10 . To prevent abrasion of the pattern, it is coated with 11 layers of clear lacquer. The thickness of the lacquer layer 11 and the thickness of the paper 7 are not shown to scale in FIG. 2 . The varnish 11 is transparent and is admixed with wear-resistant particles 12 for increased wear resistance. The particles 12 reach all the way to the surface of the paint. Furthermore, the lacquer surface has a surface relief-like structure 13 which exactly matches the pattern pattern 8 on the paper 7 . The depressions and elevations of the surface-relief-like structure 13 overlap respectively with the pattern areas 9 or 10 defined by the pattern pattern 8 . The depression of the surface relief-like structure 13 is caused by chemicals applied before the lacquer layer, which react with the lacquer after the lacquer 11 has been applied. In Fig. 2 it can be seen the deep position of the relief-like structure 13 (depression 13a), which is protected with a thin paint layer, and the area of the higher position of the surface relief-like structure 13 (protrusion 13b), which is protected by a thin layer of varnish. Thicker paint layer protection. The locations 13 a where the surface relief-like structure is deep overlap with the pattern area 9 of the pattern pattern 8 . In this way, the tactile and visual impression is supplemented and a particularly good imitation of the floor surface is produced. Depressions in the varnish layer 11 can reach up to the printing paper 7 at most. This depression has no protective lacquer layer. These depressions should preferably have a small area so that they effectively protect the surrounding raised areas from wear.

Use layer prefabrication as shown in Figure 2. To produce the floor panels 1 or 2 , the prefabricated service layers 5 or 6 are placed on the support panels 3 or 4 .

According to FIGS. 1 and 3 , floor panels 1 and 2 place the undersides of support plates 3 and 4 made of wood on a foundation U to be laid, for example a soft footstep-sound-suppressing foundation.

The support plates 3 and 4 of the floor panels 1 and 2 are chamfered at the upper edges. In this example the edge chamfer is formed by the milled radii R1 and R2. The radius R1 of the carrier plate 3 is covered with the application layer 5 . The radius R2 of the support plate 4 of the adjacent floor panel 2 is covered with the application layer 6 . The edges of the floor panels 1 and 2 are slightly deeper at their abutment than the surface of the floor panels 1 and 2 . In the installed state they are therefore protected against wear and damage.

Floor panels 1 and 2 have interlocking profiles. They are designed as modified groove and tenon profiles 14 or 15 . According to Figures 1 and 3, the tenon 15a fits positively in the groove 14a, where, at the undercut between the tenon profile 15 and the groove profile 14, the interlocking floor panels 1 and 2 are prevented from being placed The tenon profile 15 is extracted from the groove profile 14 when on the foundation U to be laid. Of course, conventional groove and tongue profiles can also be used, which have no undercuts and have to be glued or otherwise taken.

Panel floors are often laid floating. That is to say, they have a clearance with respect to the wall of the room in which they are laid. Furthermore, in order to dampen the sound of footsteps, a soft foundation is often used for laying the foundation U for the floor panels 1 and 2 . In order to facilitate the sinking of the floor into this soft foundation at the joint position of the floor panels 1 and 2, the form-locking interlocking profiles 14 and 15 form a common hinge G in the interlocked state, as shown in Fig. 1 and below to be illustrated in Figure 3. The flexibility of the hinges incorporated in this connection prevents damage to the interlocking profiles.

3 and 4 show another embodiment of a floor panel 1 or 2 with interlocking profiles 14 and 15 . The geometric design and function of the interlocking profiles 14 and 15 correspond to the above-described embodiment according to FIG. 1 . Therefore, the same reference numerals are used for the same features.

In FIG. 3 the only difference from the embodiment according to FIG. 1 lies in the edges of the floor panels 1 and 2 . In FIG. 3 the layer 5 or 6 is introduced beyond the chamfered edges of the carrier plates 3 and 4 further into the butt edge seam. At the edge of the floor panel 1 , the covering with the layer 5 reaches almost as far as the upper side of the tenon 15 a of the tenon profile. At the edge of the floor panel 2 , the free ends of the upper channel walls of the channel profile 14 are almost completely covered with the service layer 6 . The entire joint of the interlocking groove and tenon profiles 14 and 15 has a labyrinthine course. This joint has a part facing the upper side of the floor panels 1 and 2 and a part facing the lower side of the floor panels 1 and 2 . The tenons 15a and grooves 14a are located generally in the center of the support plate, between said seam portions. The part of the seam facing the upper side of the floor panels 1 and 2 is more susceptible to the penetration of moisture and dirt during daily use. In the remainder of the seam less water and dirt penetrate. For normal use of the floor panels 1 and 2 in the domestic context, it is therefore sufficient to cover in the region of that joint portion facing the upper side of the floor panels 1 and 2 .

FIG. 4 shows a particularly simple embodiment of the floor panels 1 and 2 shown already placed on the foundation U to be laid. The edges of the support plates 3 and 4 of these floor panels are not chamfered. The upper surfaces of the support plates 3 and 4 are flat. The application layers 5 and 6 are arranged on the flat upper surface of the support plate 3 and 4 . Use the ends of layers 5 and 6 butted against each other. The tenon profile 15 and the groove profile 14 have undercuts which connect adjacent panels. The tenon profile 15 and the groove profile 14 form a common hinge G. Of course, the support plates 3 and 4 can also choose to adopt other form-locking interlocking profiles, or have traditional profiles without undercuts but must be connected by glue.

Table of reference signs

1.2 Floor panel 3.4 Support board 5.6 Use layer 7 Paper 8 Pattern pattern 9.10 Pattern area 11 Paint 12 Wear-resistant particles 13 Surface relief structure 13a Concavity 13b Protrusion 14 Groove profile 14a Groove 15 Tenon Profile 15a tenon G hinge R1, R2 radius U foundation to be laid

Claims (6)

1. floor panel (1,2), comprise support plate (3,4), on support plate, add one and use layer (5,6), this use floor has one to be divided into different patterns district (9 ornamentally, 10) pattern (8), wherein, ornamental pattern (8) prevents wearing and tearing by means of wear-resisting particle (12), and, use layer (5,6) there is a kind of embossment shape structure (13) that comprises depression (13a) and protuberance (13b) on surface, wherein, depression (13a) is overlapping and to swell other pattern districts (10) of (13b) and decoration pattern (8) overlapping with the pattern district (9) of regulation, and it is characterized by: decoration pattern (8) covers with transparent enamelled coating (11); The depression (13a) of embossment shape structure (13) causes by a kind of chemicals that reacts with lacquer; And wear-resisting particle (12) is inserted in the enamelled coating (11).

2. according to the described floor panel of claim 1, it is characterized by, decoration pattern (8) and enamelled coating (11) are located on the prefabricated facing paper (7); And at finished product state, facing paper (7) is connected with support plate (3,4).

3. according to the described floor panel of claim 2, it is characterized by, the facing paper of japanning (7) sticks with glue agent and is placed on the support plate (3,4).

4. according to the described floor panel of one of claim 1 to 3, it is characterized by, the facing paper of japanning (7) constitutes seamed edge at least at two opposed seamed edge places of support plate (3,4) part coats.

5. according to the described floor panel of one of claim 1 to 4, it is characterized by, support plate (3,4) has the seamed edge of corner cut at its outward flange in that side of using layer (5,6).

6. according to the described floor panel of one of claim 1 to 5, it is characterized by, two opposed corner cut seamed edges of support plate (3,4) are added with self-adhering type decorating film layer.

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