Method Of Preparation Of A Decorated Wall Or Floor Panels

Abstract

The present disclosure relates to a method for producing a decorated wall or floor panel, comprising the method steps: a) providing a first molten polymer mass and a second molten polymer mass; b) extruding the molten polymer masses, wherein in particular each polymer mass is extruded by a separate extruder, wherein the molten polymer masses are layered on top of each other; c) expelling the layered molten polymer masses through a die; d) calibrating the layered molten polymer masses in order to form a plate-shaped carrier comprising at least one carrier layer comprising the first polymer mass and a sealable layer contacting the carrier layer and comprising the second polymer mass. Furthermore, the disclosure relates to plate-shaped carriers and decorative panels produced in this way, and to a device for carrying out the method.

Claims

1. A method for producing a decorated wall or floor panel, comprising the steps of: a) providing a first molten polymer mass and a second molten polymer mass; b) extruding the molten polymer masses, wherein in particular each polymer mass is extruded by a separate extruder, wherein the molten polymer masses are layered on top of each other, c) expelling the layered molten polymer masses through a die; d) calibrating the layered molten polymer masses in order to form a plate-shaped carrier comprising at least one carrier layer comprising the first polymer mass and a sealable layer contacting the carrier layer and comprising the second polymer mass.

2. The method according to claim 1, wherein the first polymer mass comprises a solid material, wherein the solid material preferably comprises a layered silicate powder, and wherein the solid material comprises particularly preferably talc.

3. The method according to claim 1, wherein the second polymer mass comprises a third polymer, wherein the third polymer is a vinyl copolymer, wherein the third vinyl copolymer preferably comprises a vinyl terpolymer, more preferably a polypropylene-based vinyl copolymer, particularly preferably a polypropylene-ethylene-butylene copolymer.

4. The method according to claim 1, wherein in step a) a third molten polymer mass is additionally provided and the plate-shaped carrier formed in step d) additionally comprises at least one backing layer contacting the carrier layer and comprising the third polymer mass.

5. The method according to claim 1, wherein the molten polymer masses are extruded in such a way that the carrier layer has a layer thickness of greater than or equal to 60% to less than or equal to 95%, in particular less than or equal to 90%, of the thickness of the plate-shaped carrier.

6. The method according to claim 1, wherein the calibration is carried out by means of an arrangement of a plurality of rotatable rollers, wherein the individual rollers are arranged one above the other or one behind the other and each individual roller forms at least one calibration gap with adjacent rollers, wherein the adjacent rollers form a pair of rollers through which the molten polymer masses layered one on top of the other are guided, wherein the calibration gap heights can be variably adjusted by means of a horizontal and/or vertical movement of individual rollers during the production process.

7. The method according to claim 6, wherein the molten polymer mass layered on top of each other is guided through a plurality of pairs of rollers.

8. The method according to claim 1, wherein the method further comprises the method step: e) applying a film onto at least a partial area of the sealable layer of the plate-shaped carrier.

9. The method according to claim 8, wherein the film comprises at least one top layer, wherein the top layer preferably comprises an inner side, an outer side and a decorative layer optionally applied to the inner side of the top layer, wherein the film is applied to the sealable layer in such a way that the outer side of the top layer faces away from the plate-shaped carrier.

10. The method according to claim 9, wherein said top layer comprises a fourth polymer, wherein said fourth polymer is a vinyl polymer, preferably consists essentially thereof, wherein said fourth vinyl polymer may be a homopolymer or a copolymer, wherein the fourth vinyl polymer preferably comprises a polypropylene-based vinyl polymer, particularly preferably a polypropylene copolymer, preferably selected from the group consisting of a propylene-ethylene random copolymer, a propylene-ethylene block copolymer, and a polypropylene-ethylene-butylene copolymer.

11. The method according to claim 7, wherein the film comprises a laminating layer, wherein the laminating layer is preferably applied onto the decorative layer applied to the inner side of the top layer, wherein the laminating layer is particularly preferably bonded to the decorative layer via a laminating adhesive.

12. The method according to claim 7, wherein the film is applied during the calibration in method step d), wherein preferably the film is applied downstream the first pair of rollers, and preferably upstream the sixth calibration roller, more preferably upstream the fifth, particularly preferably upstream the fourth, in particular upstream the third calibration roller.

13. The method according to claim 8, wherein the method further comprises the step f) structuring the top layer, wherein the top layer is preferably formed by a structured roller of an embossing calender.

14. The method for producing a decorated wall or floor panel, characterized in that the device comprises means for carrying out the method according to claim 1.

15. A plate-shaped carrier for a decorated wall or floor panel produced according to a method according to claim 1, comprising at least a carrier layer comprising the first polymer mass and a sealable layer contacting the carrier layer and comprising the second polymer mass.

16. A decorative panel, produced according to a method according to claim 1.

Description

DRAWINGS

[0155] The disclosure is further explained below with reference to the figures and an exemplary embodiment.

[0156] FIG. 1 shows a schematic cross-sectional view of a device configuration for carrying out the method according to the disclosure;

[0157] FIG. 2 schematically shows a top view of a device configuration for carrying out the method according to the disclosure;

[0158] FIG. 3 schematically shows the guiding of molten polymer material through a calibration roller arrangement;

[0159] FIG. 4 schematically shows the guiding of molten polymer material through a calibration roller arrangement;

[0160] FIG. 5 schematically shows the guiding of molten polymer material through a calibration roll arrangement with an enlarged section; and

[0161] FIG. 6 schematically shows a cross-sectional view of one way of carrying out the method according to the disclosure.

DETAILED DESCRIPTION

[0162] The device 1 according to FIG. 1 is suitable for a process for producing a decorated wall or floor panel. FIG. 1 shows in cross-section the possible structure of the device for producing decorated panels 1, wherein in this figure in particular the assemblies extrusion device 2 with die 5, main roller pair 3 and calibration roller arrangement 4 are shown. In this embodiment, 6 calibration rollers 7 are shown, each of which can be controlled independently in their X, and Y positions. A possible rotation direction sequence for the individual calibration rollers 7 is indicated by the arrows. The device 1 schematically shows the extrusion device 2, which for each molten polymer mass is divided into an extruder (not shown separately) for thermal treatment of polymer granules and the actual die 5, wherein the die is a multi-channel die or optionally a feed block is arranged between the extruders and the die or the multi-channel die (not shown) by which the molten polymer masses are layered on top of each other. The molten polymer strand exiting the die can be passed through the roller gap of the main roller arrangement 3 comprising the individual main rollers 6. The height of the roller gap between the two main rollers 6 can be variably adjusted by moving the main rollers 6 relative to each other. After the molten polymer masses layered on top of each other have undergone an initial shaping and, if necessary, cooling by the main roller gap, the strand is transferred to the calibration roller arrangement 4. In the calibration roller arrangement 4, the molten polymer strand is further reduced in height or calibrated. The strand is guided through the gaps between the individual calibration rollers 7 and its height is changed as a function of the gap distance. The individual calibration rollers 7 do not always have to be disposed the same distance apart, so that different gap heights can be set between the calibration rollers 7 during the process. The calibration rollers 7 also do not have to have the same height, but can also be arranged offset to each other. This can change the mechanical stretch properties of the molten polymer strand. After calibration by the main roller arrangement 3 and the individual calibration rollers 7, the calibrated and smoothed material can be provided with a decoration via a printing unit (not shown). Furthermore, the decorated surface of the panel can be provided with one or, if necessary, further layers, such as protective layers.

[0163] FIG. 2 shows a top view of a device 1 according to the disclosure. The extrusion device 2 is shown, comprising an extruder and a die, which transfers a molten polymer strand of polymer masses layered on top of each other to the main roller arrangement 3. The distance between the main roller arrangement 3 and the extrusion device 2 is variable and can be varied, for example via controlled electric motors. After the molten polymer mass has passed through the gap of the main roller arrangement 3, the carrier, which has been reduced in height and optionally been cooled already somewhat by the main roll arrangement 3, is guided into the calibrating roller arrangement 4. The calibration roller arrangement 4 consists of the individual calibration rollers 7, which form respective gaps between them through which the initially calibrated carrier is guided and further formed. The individual calibration rollers 7 can be moved as a whole or each separately in their relative position to one another. Furthermore, it is possible that the individual calibration rollers 7 are controlled in their roller surface temperature as a whole or separately.

[0164] FIG. 3 shows a possible guidance of the molten polymeric carrier 9 through the calibration roller gaps. By resting on the calibration rollers 7, the molten polymeric carrier 9 can be cooled, for example. In this arrangement of the individual calibration rollers 7, the thickness of the molten polymeric carrier 9 is rather changed by the mechanical tension of the rollers. The individual calibration rollers 7 are too far apart for the molten polymeric carrier 9 to experience a direct squeezing or compression through the gap between the calibration rollers 7.

[0165] FIG. 4 shows a similar calibration roller arrangement 4 comprising two calibration rollers 7 as in FIG. 3, wherein the calibration rollers 7 are closer together and form a gap which is smaller than the thickness of the molten polymeric carrier 9. Due to the fact that the molten polymeric carrier 9 is at least partially thicker than the calibration gap, the height of the molten polymeric carrier 9 is levelled out by the calibration gap between the calibration rollers 7.

[0166] FIG. 5 shows again the calibration roller section of FIG. 4 with an enlarged section. In the enlarged section, it can be seen that excess material of the molten polymeric carrier 9 is pushed up at the beginning of the calibration gap. As a result, the height of the molten polymeric carrier 9 is adjusted to the height of the calibration gap. The height of the calibration gap and thus the carrier height can be adjusted by the spacing of the calibration rollers 7. According to the disclosure, it is advantageous that the calibration rollers 7 are disposed so close together that as little ambient air as possible can get between the calibration rollers 7 and the molten polymeric carrier 9. The narrow pass through the gap ensures that as little additional air as possible is forced into the carrier surface. The latter can contribute to an improved calibrated carrier surface.

[0167] FIG. 6 shows a further embodiment of a device 1 for producing decorated panels according to the disclosure. The device 1 also comprises an extrusion device 2, for example with a wide slot die and an extruder. The molten polymeric mass is extruded through the die and passes via the gap of the main rollers 3 to the calibration roller arrangement 4 comprising the individual calibration rollers 7. In this figure, it is shown that the individual calibration rollers 7 do not necessarily have to be at the same height relative to one another. By deflecting a calibration roll 7 in height, for example, the mechanical forces and also the cooling properties can be changed over an air gap. Furthermore, the figure shows that within the calibration roller arrangement 4 comprising the different calibration rollers 7, a film 10 can be applied onto at least a partial area of the sealable layer of the plate-shaped carrier, which foil 10 is present, for example, as a rolled product and can be introduced at various locations of the calibration roller arrangement 4. By applying the film 10 within the calibration roller arrangement 4, an additional mechanical treatment of the layer can be carried out by the calibration rollers 7, which can lead to a better adhesion of the film to the carrier. Furthermore, it can be ensured in this way that the application of the film 10 does not cause the height of the carrier to deviate from the desired dimensions, since both the carrier and the film 10 pass through the final calibration gap. After application of the film 10, the carrier can be either further tempered/cooled in a defined manner or mechanically post-processed via further means 11. Suitable further means 11 for this purpose may be cooling or tempering surfaces or mechanical mills for further profiling, for example of the carrier edges.