LU100188B1 - Floor or wall covering production method - Google Patents

Abstract

A method of producing a floor or wall covering is presented. The method comprises bonding solid particles onto the front face of a carrier plate, the solid particles comprising or consisting of solid inorganic particles, the bonding being effected by scattering a powder comprising solid inorganic particles on the front face and forming a surface layer there from. The carrier plate is a composite carrier plate, comprising a mineral or polymeric cement and a mineral or organic, preferably fibrous, filler or reinforcement material, provided that at least one of the cement and the filler or reinforcement material comprises a mineral material or mineral material mixture representing at least 25%, preferably at least 35%, more preferably at least 50%, by weight, of the carrier plate.

Description

DESCRIPTION

FLOOR OR WALL COVERING PRODUCTION METHOD

Field of the Invention [0001] The disclosure relates to the field of finishing work, especially for but not limited to buildings. In particular, the disclosure relates to floor or wall coverings. An aspect of the invention relates to wear resistant surfaces for floor or wall coverings comprising solid inorganic particles.

Background of the Invention [0002] Laminate floors are well known. Laminated floors typically have 6-12 mm thick fiberboard core, a sub-millimeter thick upper decorative surface layer and a submillimeter thick balancing layer on the bottom side.

[0003] The surface layer generally consists of two layers of paper, separately applied one on top of the other. The lower of the two layers provides the decoration function and may consist of a melamine formaldehyde (hereinafter: “melamine” for simplicity) impregnated printed paper. The upper of the two layers is the wear layer and may be a melamine impregnated transparent overlay paper, which comprises small wear resistant aluminium oxide particles.

[0004] Other types of floor coverings may also use wear layers comprising “wear-resistant” particles. The décor may be applied by any suitable process, e.g., printing (rotogravure, digital printing, etc.) directly on the core layer or on a printing substrate that is laminated on the core layer. The print is then covered with the protective wear layer, which may take the form of an overlay, a plastic foil, a lacquer, etc. So called “Luxury Vinyl Tiles” (LVT floorings) are an example of a layered product. LVT comprises a PVC-based structural layer and a printed decorative PVC foil on the upper side. A transparent vinyl wear layer protects the decorative foil. The protective layer may include a polyurethane coating that provides additional wear and stain resistance.

[0005] Wear layers may also be used if the production of the floor covering involves no printing step. Ceramic tiles are one example.

Summary of the Invention [0006] Aspects of the present invention are particularly suitable for manufacture of floor or wall coverings, which are formed of floor or wall panels comprising a rigid, machinable core, optionally a décor, and a wear-resistant protective layer (“wear layer”) on top. Embodiments may be fibrocement floors and rigid thermoplastic, thermoset or radiation-cured polymeric floors comprising mineral cement material and/or mineral filler or reinforcement material.

[0007] A first aspect of the invention relates to a method of producing a floor or wall covering, comprising: o providing a composite carrier plate, comprising a mineral or polymeric cement and a mineral or organic, preferably fibrous, filler or reinforcement material, provided that at least one of the cement and the filler or reinforcement material comprises a mineral material or mineral material mixture representing at least 25%, preferably at least 35%, more preferably at least 50%, by weight, of the carrier plate, the carrier plate having a front face and a back face; o bonding on the front face a surface layer obtained from a scattered powder comprising solid inorganic particles.

[0008] Additionally or alternatively, the bonding may also be effected by incorporating solid particles into a polymeric anchoring matrix hardened in situ (i.e. on the front face of the composite carrier plate), the solid particles comprising or consisting of solid inorganic particles. The solid particles could be provided as the powder that is scattered on the front face.

[0009] It should be noted that the expression “solid inorganic particles” designates inorganic particles in the solid state. The solid inorganic particles do not undergo a phase change during the bonding step and remain distinguishable (i.e. do not form a uniform phase) with the anchoring matrix into which they are incorporated. Preferably, the solid inorganic particles comprise ceramic particles, e.g., carbide, nitride and/or oxide particles. It should be noted that the solid inorganic particles may be provided as part of a particle mixture or a powder comprising other particles, e.g. organic particles. The other particles, if any, could participate in the formation of the anchoring matrix and become indistinguishable from it in the final product. Alternatively, the other particles could be embedded in the polymeric anchoring matrix substantially in the same way as the inorganic particles and remain distinguishable in the final product.

[0010] The solid inorganic particles could be selected, e.g., from the group consisting of: AI2O3, S12O, SÎ3N4, SiOxNx, AIN, BN, ΑΙΝΟ, MgO, ZnO, SnO2, NiO, ZrO2, Cr2O3, MoO2, RuO2, CoOx, CuOx, VOx, FeOx, MnOx, T1O2, CaF2, BaF2, MgF2, SiC, WC, B4C, ternary and/or complex oxides involving one or more of the elemental species of the mentioned compounds and mixtures thereof. Preferably, the solid inorganic particles have a particle size of -20 +635 mesh, more preferably of -35 +635 mesh, still more preferably of -40 +635 mesh, even more preferably of -45 +400 mesh, yet more preferably of -45 +325 mesh, and most preferably of -60 +270 mesh. As used herein, mesh sizes are indicated as US standard mesh sizes (i.e. the number of openings per linear inch of the sieve). A "+" before the mesh indicates the particles are retained by the sieve, whereas a before the mesh size indicates the particles pass through the sieve. A particle size indicated as -20 +400 mesh thus means that at least 90% (by weight) of the particles pass through the 20 mesh sieve but are retained by the 400 mesh sieve. See e.g. page T848 of the Aldrich 2003-2004 Catalog/Handbook of Fine Chemicals for reference. The following table indicates the correspondence between opening size and US mesh number:

[0011] Embodiments of the invention could use the following particle sizes (other particle sizes not being excluded in alternative embodiments): -25 +30 mesh, -30 +35 mesh, -35 +40 mesh, -40 +45 mesh, -45 +50 mesh, -50 +60 mesh, -60 +70 mesh, -70 +80 mesh, -80 +100 mesh, -100 +120 mesh, -120 +140 mesh, -140+170 mesh, -170+200 mesh, -200+230 mesh, -230+270 mesh, -270 +325 mesh, -325 +400 mesh, -60 +325 mesh, -60 +230 mesh, -60 +200 mesh, -80 +270 mesh, -100 +230 mesh, -120 +200 mesh.

[0012] According to an embodiment, the bonding comprises contacting the solid particles with a thermoplastic resin at a temperature at which the thermoplastic resin is in liquid state, the thermoplastic resin being selected so as to wet the solid particles and the front face when in the liquid state, and hardening the so-obtained matrix by cooling down the thermoplastic resin from the temperature at which the thermoplastic resin is in liquid state to a lower temperature. The thermoplastic resin may be applied on the front face at a temperature at which the thermoplastic resin is in solid state and then heated to a temperature above its melting temperature. Alternatively, the thermoplastic resin could be applied on the front face in liquid state.

[0013] According to an alternative embodiment, the bonding comprises contacting the solid particles with an uncured thermosetting or radiation-curable resin, the uncured thermosetting or radiation-curable resin being selected so as to wet the solid particles and the front face when in the uncured state, and hardening the thermosetting or radiation-curable resin.

[0014] The solid inorganic particles could be coated with a thermoplastic, radiation-curable or thermosetting resin, e.g., melamine or the like, so as to form “two-component” or “multi-component” particles with a solid inorganic core and a coating that surrounds (or substantially surrounds) the core. The anchoring matrix could be obtained by curing the thermoplastic, thermosetting or radiation-curable resin.

[0015] Part of or all (preferably only part of, i.e. not all) the thermoplastic resin in liquid state or part of or all (preferably only part of, i.e. not all) the uncured thermosetting or radiation-curable resin, could be applied on the front face by digital printing. As used herein, the term “digital printing” designates a digitally controlled printing process involving ejection of a fluid from a print head, print nozzle or the like. The fluid may be a transparent, semi-transparent or opaque, colored or colorless ink.

[0016] The solid particles may be applied onto the front face after a first digital printing step and possibly before a second digital printing step. The first digital printing step could include the printing of a polymeric (or other) binder pattern that the solid particles adhere to. The polymeric (or other) binder pattern could consist of isolated islands (of whatever shape: dots, crosses, polygons, etc.), of a coherent pattern (of whatever shape, e.g. a regular or irregular lattice, grid, etc.) or of a mixture of coherent regions and isolated islands. The printed binder could be a temporary binder (i.e. one that vanishes in the further course of the process, e.g. by evaporation or by sublimation, etc.) In case of a temporary binder another matrix-forming (permanent) binder may be necessary to anchor the solid inorganic particles on the front face.

[0017] According to an embodiment, the carrier plate comprises a fibrocement plate (with a mineral cement). Alternatively, the carrier plate comprises a rigid plastic plate (with a polymeric cement). At least one of the cement and the filler or reinforcement material comprises a mineral material or mineral material mixture representing at least 25%, preferably at least 35%, more preferably at least 50%, by weight, of the carrier plate. Higher contents of mineral materials, e.g. at least 60% by weight, 70% by weight, 75% by weight, 80% by weight or even more, may be possible in specific embodiments.

[0018] According to embodiments of the invention, the rigidity of the carrier plate is such that it elastically deforms only to a radius of curvature of 50 cm or more, i.e. bending of the carrier plate to a radius of curvature smaller than 50 cm either leads to plastic deformation of the carrier plate or breaking thereof. More rigid carrier plates are not excluded and may be preferred in some embodiments. For instance, the rigidity may be such that the carrier plate elastically deforms only to a radius of curvature of 75 cm or more, or 1 m or more, or 1.5 m or more.

[0019] According to an embodiment, the fibrocement plate comprises cementitious binder and organic fibers, e.g. polymeric fibers, cellulosic fibers, a mixture of polymeric fibers and cellulosic fibers. As used herein, the expression “cementitious binder" designates a mineral cement, e.g. a hydraulic cement or a non-hydraulic cement. Preferably, the cementitious binder is a hydraulic cement (e.g. Portland cement, blast furnace cement, etc.). Preferably, the hydraulic is a mixture comprising belite (2CaOSiO2), alite (3CaOSiO2), tricalcium aluminate (3CaOAl2O3) and/or brownmillerite (4CaO-AI2O3· Fe2O3).

[0020] The carrier plate may be cut into smaller floor or wall covering elements after the bonding step by cutting along cutting lines. Preferably, the bonding step is carried out in such a way that the cutting lines are spared from at least the inorganic particles. That way, it is avoided that the cutting tool has to cut through regions in which the inorganic particles are present and could give rise to excessive abrasion of the cutting tool.

[0021] The scattered powder could comprise a mixture of the inorganic particles and organic particles. The organic particles are preferably polyamide-based, uncured or cured epoxy-resin-based, polyurethane-based, melamine-based, or polyurea-based.

[0022] The organic particles could comprise solid-state thermoplastic, radiation-curable or thermosetting resin particles, which are liquefied in the bonding step and thereafter hardened so as to form the polymeric anchoring matrix.

[0023] The organic particles could comprise (previously) cured thermoset or (previously) radiation-cured particles. I [0024] The inorganic particles preferably have a Mohs hardness of at least 3, preferably of at least 4, more preferably of at least 5, still more preferably of at least 6 and most preferably of at least 7.

[0025] According to an embodiment of the invention, the inorganic particles have an absolute hardness higher than the absolute hardness of the carrier plate.

[0026] A further aspect of the invention relates to a floor or wall covering element produced in accordance with a method described herein.

Brief Description of the Drawings [0027] By way of example, preferred, non-limiting embodiments of the invention will now be described in detail with reference to the accompanying drawings, in which:

Fig. 1 : is a cross-sectional view of a part of a composite carrier plate comprising on its front side a wear layer including solid wear-resistant particles;

Fig. 2: is a cross-sectional view of a another part of the composite carrier plate of Fig. 1;

Fig. 3: is an illustration of equipment usable for applying a wear layer including solid wear-resistant particles onto a rigid carrier plate.

Description of Preferred Embodiments [0028] In the following description, the to-be-exposed surface of the floor or wall covering is referred to as the “front side", while the opposite side of the floor or wall covering, facing the wall or the subfloor, is called the “rear side” or “back side”.

[0029] Wear layers of floor or wall coverings comprising wear-resistant particles are known for particular types of substrates.

[0030] Figs. 1 and 2 illustrate a floor or wall covering element 10 (panel, plank, tile, etc.) produced in accordance with an embodiment of the present invention. The floor or wall covering element 10 comprises a structural core 12, a wear layer 14 with solid wear-resistant particles on the front side, and a backing or balancing layer 16 on the back side.

[0031] The floor or wall covering element 10 comprises mechanical connection profiles 18, 20 along at least two of its edges. The interlocking elements or connectors are of complementary shapes. Fig. 1 shows the first connector 18, which can mechanically engage with the second connector 20, shown in Fig. 2. The shapes of the connectors 18, 20 are preferably such that they effect an interlocking when the connectors are engaged. Preferably, the interlocking occurs both in the direction normal to the front side and in the direction parallel to the front side and normal to the edges that are put together. It should be noted, however, that embodiments of the connectors providing interlocking effect only in one of these directions are not excluded and may even be preferred in certain applications. The connectors shown in Figs. 1 and 2 comprise, respectively, a first locking element in the form of a protruding tongue 22 and a second locking element in the form of a groove 24. The rear part of the groove 24 is delimited by a bracket 26, which is shaped complementarily to the rear side 28 of the tongue 22.

[0032] The connection profiles 18, 20 are mechanically machined into the edges of the structural core 12. The rigidity of the composite carrier plate forming the structural core 12 is, therefore, chosen such that the machining (e.g. cutting, milling) can be effected without difficulty. This may be achieved using a composite carrier plate that comprises a mineral or polymeric cement and a mineral or organic, preferably fibrous, filler or reinforcement material, wherein at least one of the cement and the filler or reinforcement material comprises a mineral material or mineral material mixture representing at least 25%, preferably at least 35%, more preferably at least 50%, by weight, of the carrier plate.

[0033] The composite carrier plate forming the structural core 12 preferably consists ofa fibrocement plate comprising mineral (e.g. glass), polymeric and/or cellulosic fibers embedded in a mineral, preferably hydraulic, cement. As used herein, the term “cellulosic fibers” is intended to include lignocellulosic fibers (e.g. sisal fibers, hemp fibers, bamboo fibers, wood pulp, etc.). The fibers may be microfibrillated. Preferably, the fibrocement comprises a mixture of cellulosic fibers of two or more different SR fineness degrees (measured according to ISO 5267-1 ).

[0034] As an alternative to a fibrocement plate as the structural core layer, a polymer-based core layer charged with at least 25% by weight (with respect to the total weight of the carrier plate), preferably more, ofa mineral filler or reinforcement material. Filler or reinforcement material could comprise, e.g., calcium carbonate, limestone, gypsum, ground stones, glass fibers, clay, or the like. The presence of organic filler or reinforcement materials is not excluded. For instance, the composite carrier plate could comprise cellulosic or polymeric fibers (e.g. wood flour or saw dust).

[0035] The wear layer 14 comprises solid inorganic particles embedded within a polymeric anchoring matrix that has been hardened in situ on the composite carrier plate. The solid inorganic particles may e.g. comprise or consist of ceramic particles, e.g., carbide, nitride and/or oxide particles. Particularly preferred species are the following ones: AI2O3, S12O, S13N4, SiOxNx, AIN, BN, ΑΙΝΟ, MgO, ZnO, SnO2, NiO, ZrO2, Cr2O3, Μοθ2, RuO2, CoOx, CuOx, VOx, FeOx, MnOx, T1O2, CaF2, BaF2, MgF2, SiC, WC, B4C, as well as ternary and/or complex oxides involving one or more of the elemental species of the mentioned compounds and mixtures thereof.

[0036] The solid wear-resistant particles may be applied in patterns so as to create (substantially) wear-resistant-particle-free zones with lower wear resistance. These (substantially) wear-resistant-particle-free zones are preferably arranged where machining of the carrier plate front face is necessary. The (substantially) wear-resistant-particle-free zones preferably have an areal density (in terms of mass per area) of solid inorganic particles of less than 10% of the areal density of solid inorganic particles of the entire front face.

[0037] The solid wear-resistant particles may be bonded and positioned in well-defined patterns on the composite carrier plate. The application of this wear layer may be effected prior to cutting the composite carrier plate into individual floor or wall covering elements and machining the edges. Notwithstanding that, the wear layer could alternatively be applied on the individual floor or wall covering elements (before or after machining of the edges).

[0038] Fig. 3 shows a possible embodiment of such an application process. A pattern of adhesive 30 may be formed on the composite-material carrier plate 32 by digital printing. Reference number 34 designates a digital printer. The ink may be, e.g., a polymer-based thermosetting ink but any other suitable ink could be used as well. The digitally printed pattem may be continuous, continuous with blanks, discontinuous, as well as partially continuous and partially discontinuous.

[0039] The ink (adhesive) should remain uncured at least until a powder consisting of or comprising the solid inorganic wear-resistant particles has been scattered thereon at a scattering station 36. The solid inorganic particles could be mixed with other particles, e.g. spray-dried melamine powder, granules of thermoplastic or thermosetting resin and/or with solid cured organic particles.

[0040] The scattering station 36 comprises one or more storage hoppers 38 containing the particles 39 and a dispenser 40 that scatters the particles 39 onto the (partially) adhesive-coated front face of the carrier plate 32. The particles may be provided as a mixture from one hopper but, preferably, the scattering station comprises plural hoppers containing each a particular type of particles. Providing different hoppers for different particle species may be helpful in order to avoid segregation of the particles. A blender (not shown) may be arranged between the hoppers and the dispenser in order to blend the particles in the desired proportions. Alternatively, one could use different dispensers, each dispenser being connected to one hopper (or a subgroup of the hoppers).

[0041] A first part of the particles scattered on the front face of the carrier plate fall on the adhesive pattern. A second part of the particles fall on the blanks. The particles having fallen on the adhesive are (at least lightly) bonded to the carrier plate 32, whereas the other particles are not bonded at all or at least significantly less. The non-bonded particle are thereafter removed from the front face using a blower, brushes and/or, as in the illustrated embodiment, an aspirator 42. The aspired particles are preferably fed back to the hopper(s) 38. The remaining bonded particles form a pattern of solid wear-resistant particles that corresponds to the digitally printed pattern of adhesive. One may repeat this process in order to apply plural layers of solid wear-resistant particles. The adhesive patterns applied in the different layers may be the same or different.

[0042] After the particles have been scattered on the carrier plate, they may be pressed gently into the adhesive pattern in order to achieve improved adhesion. Gently pressure may be applied, e.g., by means of one or more rollers. Another option for making the particles better adhere to the carrier plate may be the application of heat downstream of the scattering station but upstream of the loose-particle removal station. Heat could be applied using an oven or via IR (infrared) lamps.

[0043] As an alternative to applying adhesive to the carrier plate, one could print a pattern of an ink that represents a solvent of an organic compound admixed to the solid inorganic particles or coating them. In that case, when the particles or the particle mixture contacts the printed pattern, the solvent dissolves the organic compound at least partially whereby the particles are bonded to the carrier plate.

[0044] In the illustrated embodiment, additional polymeric material is applied on top of the particles in a subsequent coating step. The additional polymeric material is preferably applied by digital printing. Alternatives would be lamination of a plastic sheet, scattering of a polymer dry blend or the like. In the illustrated embodiment, the additional polymeric material is applied by a digital printing station 44. Downstream of the digital printing station 44, the polymeric anchoring matrix is formed by hardening the additional polymeric material and the adhesive pattern 30. For instance, the additional polymeric material could be a thermosetting resin that is cured in an oven 46. Alternatively, the additional polymeric material could be a thermoplastic resin or a radiation-curable polymer.

[0045] As illustrated in Fig. 3, the production process is preferably controlled by a computer 48 or a control station using a network of computers.

[0046] The method of the present invention may be used together with a conventional overlay sheet or decorative sheet applied on the composite carrier plate. In this case, the solid wear-resistant particles may be applied on the overlay prior or after impregnation and the overlay sheet with the solid wear-resistant particles may be applied on a decorative sheet. The solid wear-resistant particles may be applied on the decorative sheet preferably after impregnation when the decorative sheet is positioned on the composite carrier plate, which is preferably a fibrocement plate. Impregnation of the decorative sheet could be replaced by arranging the decorative sheet on a layer comprising thermoplastic, thermosetting or radiation-curable resin, e.g. in powder form.

[0047] It should be noted that the wear layer comprising the solid inorganic particles embedded in the polymeric anchoring matrix could be applied directly on the naked composite carrier plate. That variant may be particularly advantageous if the wear layer also has a decorative function. It may be worthwhile noting that aesthetically appealing decorative wear layers could be achieved using combinations of controllable parameters of the process, including, for instance: fillertypes, pigments, solid inorganic particle species, the material of the polymeric anchoring matrix and the digitally printed pattern.

[0048] Thanks to the invention, solid wear-resistant particles may applied on a composite carrier plate in a controlled and very precise manner. Specifically, the solid wear-resistant particles may be distributed and embedded in the anchoring matrix in exactly the desired pattern. Zones of the composite carrier plate that shall not comprise solid-wear-resistant particles may be easily defined.

Example 1 [0049] A fibrocement plate with a thickness of 6 mm was covered with a dense pattern of deionized water drops. A powder mix was then applied on the fibrocement plate. The powder comprised wood fibers, melamine particles, and aluminium oxide particles. The initial loading with powder was 220 g/m2. The water drops wetted parts of the powder. The dry parts of the powder were removed by aspiration whereby the average areal density of the powder decreased to about 170 g/m2. A digital print covered about 20% of the surface and the basic colour. After gently consolidating the powder layer using a roll, a digital print layer was applied. The ink was transparent water-based ink and the print pattern covered about 50% of the front surface of the fibrocement plate. A dry mix of -140 +170 mesh aluminium oxide particles (85% by weight) and similarly sized melamine formaldehyde particles (15% by weight) was scattered on the surface. The non-bonded particles were removed thereafter. The fibrocement plate was thereafter hot-pressed during 20 seconds at a temperature of 170°C and at a pressure of 38 bars. A cured anchoring layer was thereby formed, wherein the aluminium oxide particles were firmly embedded.

Example 2 [0050] A fibrocement plate with a thickness of 5.5 mm was covered digitally printed pattern of an uncured thermosetting ink capable of cross-linking with melamine. The ratio of blank areas to areas covered with ink was about 40%/60%. A dry mixture of -100+120 mesh aluminium oxide particles (75% by weight) and similarly sized melamine formaldehyde particles (25% by weight) was scattered on the surface. The initial loading with powder was 200 g/m2. After gently pressing the powder mixture onto the ink pattern, the dry parts of the powder were removed by aspiration whereby the average areal density of the powder decreased to about 110 g/m2. Additional thermosetting ink was then applied on both on the areas covered with powder and in the blank areas. The fibrocement plate was thereafter hot-pressed during 15 seconds at a temperature of 170°C and at a pressure of 40 bars. A cured anchoring layer was thereby formed, wherein the aluminium oxide particles were firmly embedded.

[0051] While specific embodiments and examples have been described herein in detail, those skilled in the art will appreciate that various modifications and alternatives to those details could be developed in light of the overall teachings of the disclosure.

Accordingly, the particular arrangements disclosed are meant to be illustrative only and not limiting as to the scope of the invention, which is to be given the full breadth of the appended claims and any and all equivalents thereof.

Claims (17)

A method for producing a floor or wall covering, comprising: providing a composite support plate comprising a mineral or polymeric cement and an inorganic or organic, preferably fibrous, fill or reinforcement material; provided that at least one of the cement and the filler or reinforcing material comprises a mineral material or mixture of inorganic materials of at least 25%, preferably at least 35%, more preferably at least 50%, by weight, the support plate, the support plate having a front face and a rear face; the fixing on the front face of a surface layer obtained from a dispersed powder comprising solid inorganic particles. The process as claimed in claim 1, wherein said solid inorganic particles comprise ceramic particles, e.g. eg, carbide, nitride and / or oxide particles. 3. The process as claimed in claim 1 or 2, wherein said solid inorganic particles are selected from the group consisting of: Al2O3, Si2O, S13N4, SiOxNx, AlN, BN, ΑΙΝΟ, MgO, ZnO, SnO2, NiO, ZrO2 , Cr2O3, MoO2, RuO2, CoOx, CuOx, VOx, FeOx, MnOx, TiO2, CaF2, BaF2, MgF2, SiC, WC, B4C, ternary oxides and / or complex oxides containing one or more elemental species of the compounds mentioned and mixtures thereof. The method according to any one of claims 1 to 3, wherein said fixing comprises contacting said solid particles with a thermoplastic resin at a temperature at which said thermoplastic resin is in a liquid state, said thermoplastic resin being selected so as to wet said solid particles and said front face when in said liquid state, and wherein said curing is effected by cooling said thermoplastic resin of said temperature at which said thermoplastic resin is in a liquid state at a temperature lower. The method as claimed in claim 4, wherein said thermoplastic resin is applied to said front face at a temperature at which said thermoplastic resin is in a solid state and wherein said thermoplastic resin is heated to said temperature at which said Thermoplastic resin is in a liquid state. The method of any one of claims 1 to 3, wherein said attaching comprises contacting said solid particles with a thermosetting or non-crosslinked radiation curing resin, said thermosetting or non-radiation curing resin. crosslinked being selected so as to wet said solid particles and said front face when in said uncrosslinked state, and wherein said curing is achieved by crosslinking said thermosetting or radiation curing resin. The method of any one of claims 1 to 6, wherein said support plate comprises a fiber cementitious plate. The process as claimed in claim 7, wherein said fibrocement-based plate comprises a cementitious binder and organic fibers, e.g. ex. a mixture of polymeric fibers and cellulosic fibers. The process as claimed in claim 8, wherein said cementitious binder is a hydraulic binder. The method according to any one of claims 1 to 9, wherein said support plate is cut into smaller floor or wall elements, after said fixing step, by cutting along cut-off lines and wherein said fixing step is performed such that said cleavage lines are free of said inorganic particles. The process of any one of claims 1 to 10, wherein said dispersed powder comprises a mixture of said inorganic particles and organic particles. 12. The process as claimed in claim 11, wherein said organic particles based on polyamide, uncrosslinked or cross-linked epoxy resin, polyurethane, melamine, polyurea. The process as claimed in claim 11, wherein said organic particles comprise a solid-state, radiation-crosslinked or thermosetting thermoplastic particle resin, which are liquefied in said fixing step and subsequently cured in such a manner. forming said polymeric anchor matrix. The method of any one of claims 11 to 13, wherein said organic particles comprise crosslinked thermosetting particles or radiation crosslinked particles. The process according to any one of claims 1 to 14, wherein said organic particles have a Mohs hardness of at least 3, preferably at least 4, more preferably at least 5, more preferably at least 4. at least 6 and most preferably at least 7. The process of any one of claims 1 to 15, wherein the inorganic particles have an absolute hardness greater than the absolute hardness of said support plate. 17. A flooring or wall element produced in accordance with the method of any one of claims 1 to 16.