Method for Producing a Multiplayer, Surface-Structured Panel, and a Panel Produced by this Method

Abstract

Provided is a method for producing a multilayer, surface-structured panel, in particular a multilayer, surface-structured flooring panel. The method includes the steps of: providing at least one plastic carrier panel, in particular in the form of a continuous strand; introducing surface structures on at least one side of the plastic carrier panel by means of embossing; applying at least one primer to the structured surface of the plastic carrier panel; printing the plastic carrier panel by direct printing to form a decorative layer; applying an anti-wear layer containing abrasion-resistant particles; applying at least one lacquer layer; and curing the layer structure.

Claims

1. A method of manufacturing a multilayer surface-textured panel, in particular a multilayer surface-textured flooring panel, comprising the steps of: providing at least one plastic carrier plate consisting of at least two layers, in particular in the form of a continuous strand, wherein the at least two-layer plastic carrier plate can be produced from at least two different plastics by means of co-extrusion, and wherein one of the layers is formed from a hard plastic and the other layer is formed from a plastically deformable, structurable plastic; introducing surface structures on at least one side of the plastic carrier plate by means of embossing; applying at least one primer to the textured surface of the plastic backing plate; direct printing of the plastic carrier plate with the formation of a decorative layer; applying a wear protection layer containing abrasion-resistant particles; applying at least one coating layer; and curing of the layer structure.

2. The method according to claim 1, wherein the plastic carrier plate is produced from a mixture containing PVC, limestone, optionally a recyclate and optional auxiliary materials by means of extrusion.

3. The method according to claim 1, wherein the plastic compound used for the lower, non-plastically deformable layer of the plastic carrier plate contains no plasticizer and the plastic compound used for the upper, structurable layer of the plastic carrier plate contains plasticizers.

4. The method according to claim 1, wherein the plastic support plate is colored by admixing dye particles.

5. The method according to claim 1, wherein the embossing of the surface structures is carried out by means of a structured plate, a structure generator, a circulating structure strip or a structured roller.

6. The method according to claim 1, wherein the surface structures or embossed structures are joints, relief and/or pores.

7. The method according to claim 1, wherein the primer to be applied to the surface of the plastic carrier plate before printing comprises at least one primer layer and/or at least one PU hotmelt (hotcoating).

8. The method according to claim 1, wherein at least one white primer is applied to the primer before printing.

9. The method according to claim 1, wherein at least one decorative layer is applied by digital printing.

10. The method according to claim 1, wherein the wear protection layer applied to the decorative layer comprises at least a first cover layer, abrasion-resistant particles and at least a second cover layer.

11. The method according to claim 10, wherein particles of corundum (aluminum oxides), boron carbides, silicon dioxides or silicon carbides are used as abrasion-resistant particles.

12. The method according to claim 10, wherein the at least one first cover layer and the at least one second cover layer comprise a UV coating or a hotcoating.

13. The method according to claim 1, wherein the at least one coating layer comprises a UV topcoat.

14. An abrasion resistant and waterproof multilayer panel producible in a process according to claim 1 comprising: at least one surface-structured plastic carrier plate, in particular a two-layer surface-structured PVC carrier plate; at least one base coat; at least one decorative layer printed by direct printing, at least one wear protection layer with abrasion-resistant particles provided on the decorative layer; and at least one coating layer provided on the wear protection layer.

15. A production line for carrying out a method according to claim 1 comprising at least one extruder; at least one device for embossing a surface structure in at least one side of a plastic carrier plate; at least one applicator for applying at least one base coat to the at least one plastic support plate; at least one printer for applying at least one decorative layer; at least one device provided downstream of the printer in the processing direction for applying at least one wear protection layer; and at least one device for applying a coating layer.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0166] The solution is explained in more detail below with reference to the figures in the drawings, using an example of an embodiment.

[0167] FIG. 1 shows a schematic representation of a production line of a multilayer panel according to one embodiment of the process according to the solution.

DESCRIPTION OF THE INVENTION

[0168] The production line shown schematically in FIG. 1 comprises a first section 1 for producing the plastic carrier plate and a second section 2 for surface processing the plastic carrier plate.

[0169] Subsection 1 initially comprises a storage container 10 for PVC powder and a storage container 11 for limestone, which are mixed together in the mixing device 13 with the addition of further auxiliary materials 12.

[0170] This powdered mixture of PVC, limestone (or chalk) and further additives can be temporarily stored in an intermediate hopper 14. The intermediate hopper 14 is arranged downstream of the mixing device in the processing direction. The extruder 15 is connected to the intermediate hopper 14 in the processing direction.

[0171] As already discussed, a compound made from the individual components in pellet form can also be used directly as the starting component for extruder 15. In this case, storage tanks 10, 11, 12, mixing device 13, and intermediate hopper 14 can be dispensed with.

[0172] The mixture (powder or compound) is fed into the extruder device 15 and pressed through a profile to form a continuous strand (SPC strand). The extruder device 15 is designed as a multi-stage extruder with zones of different temperature, with partial cooling with water. A plate-like strand (e.g. with a maximum width of 1,400 mm) is discharged from the extruder via a slot die onto a roller conveyor 16.

[0173] Two plastic compounds are provided for the extruder. The first, plasticizer-free blend for the lower, hard layer of the plastic carrier plate consists of 20% by weight PVC, 76% by weight limestone, 1.5% calcium-zinc as stabilizer, 1.5% by weight, 1% CPE as impact modifier and 1% auxiliary ACR812. The second mixture for the upper structurable layer also contains plasticizer.

[0174] The still warm endless strand is introduced into a roller device 17 for embossing the surface structure. The embossing device 17 has a structured roller with which joints, reliefs and/or pores are embossed onto the upper side of the continuous strand to match the subsequent decor.

[0175] Subsequently, the surface-textured continuous strand is cut to size and the plates are stacked (18).

[0176] Subsection 2 for surface processing of the plastic carrier plate starts with a separation and pre-treatment of the carrier plates, such as a plasma or corona treatment (not shown).

[0177] In a next step, at least one base coat, preferably a UV coating as a primer or adhesion promoter, is applied to the surface of the plastic carrier plate using a roller unit 20.

[0178] In the embodiment shown in FIG. 1, this is followed by a digital printer 21 for applying a white background, followed by one or more digital printers 22 for printing the decorative layer. The decorative printing is carried out according to the inkjet principle in a single-pass process in which the entire width of the top side to be printed is covered, with the plates being moved under the printer.

[0179] The at least one device provided downstream of the printer 22 in the processing direction for applying a UV coating as a first cover layer to the decorative layer is designed as a roller application device 23.

[0180] Downstream of the roller application device 23 for the first cover layer, a first scattering device 24 is provided for uniformly scattering the abrasion-resistant material, such as corundum, on the upper side of the plastic carrier plate. The abrasion-resistant material used is corundum F220, which measures about 45-75 μm in diameter according to FEPA standards.

[0181] The scattering device 24 essentially consists of a supply hopper, a rotating, structured spiked roller and a scraper. The application quantity of the material is determined by the rotational speed of the spreader roller. Depending on the required abrasion class of the product, between 12-25 g/m.sup.2 of corundum is spread onto the board (AC4 (according to DIN EN 16511)=20 g/m.sup.2). From the spiked roller, the corundum falls at a distance of 5 cm onto the panel provided with the decorative foil.

[0182] The scattering device 24 is followed in the processing direction by the device 25 for applying a UV coating as a second cover layer.

[0183] The final coating layer is also applied using a roller device 26.

[0184] The application devices are followed in the processing direction by devices for curing the layer structure, such as dryers and/or radiators (not shown). Suitable cooling devices and cutting devices are provided for further finishing (not shown).