METHOD FOR PRODUCING A FLOORBOARD

Abstract

A method for producing a floorboard having a topside veneer includes forming a multilayer body which includes a starting carrier plate, a plurality of veneers placed on the starting carrier plate so that a gap is formed between neighboring ones of the veneers, a resin layer including a resin provided between the starting carrier plate and the veneers, and a balancing layer arranged on a bottom side of the starting carrier plate; joining the starting carrier plate, the resin layer, the veneers and the balancing layer by pressing the multilayer body in a press; separating the multilayer body into individual boards between the neighboring veneers in a region of the gap; profiling the individual boards at side borders of the boards; and providing the individual boards with joining means.

Claims

1-14. (canceled)

15. A multilayer body comprising: a substrate; a topside veneer; a cured thermosetting resin between the substrate and the topside veneer; and a balancing layer arranged on a bottom side of the substrate, wherein the multilayer body comprises at least one cured thermosetting resin side border, wherein the at least one thermosetting resin side border is formed by curing thermosetting resin adhering to at least one outer side surface of the topside veneer.

16. The multilayer body according to claim 15, wherein the topside veneer is a plurality of veneers.

17. The multilayer body according claim 16, wherein the plurality of veneers comprises neighboring veneers, wherein the neighboring veneers are positioned spaced apart relative to each other on the substrate such that there is a gap between two neighboring veneers.

18. The multilayer body according to claim 17, wherein the gap is filled with the cured thermosetting resin.

19. The multilayer body according to claim 15, wherein the cured thermosetting resin is permeated into the topside veneer.

20. The multilayer body according to claim 19, wherein the cured thermosetting resin is visible at a surface of the topside veneer facing away from the substrater.

21. The multilayer body according to claim 15, wherein the thickness of the topside veneer is smaller than 2.5 mm.

22. The multilayer body according to claim 15, wherein the substrate is made of a wood material.

23. The multilayer body according to claim 15, wherein the substrate is made of solid wood, chipboard, wood fiber material, MDF (Medium Density Fiber Board) or HDF (High Density Fiber Board).

24. The multilayer body according to claim 15, wherein the cured thermosetting resin comprises a filler.

25. The multilayer body according to claim 15, further comprising a second cured thermosetting resin between the substrate and the balancing layer.

26. The multilayer body according to claim 16, wherein the multilayer body is a building panel or is configured to be divided into building panels.

27. The multilayer body according to claim 16, wherein the multilayer body is configured to be divided into floorboards.

28. The multilayer body according to claim 15, wherein the multilayer body comprises a plurality of thermosetting resin side borders formed by curing thermosetting resin adhering to a plurality of outer side surfaces of the topside veneer.

29. The multilayer body according to claim 15, wherein the multilayer body is rectangular with four thermosetting resin side borders.

30. A floorboard comprising: a substrate; a topside veneer; a cured thermosetting resin between the substrate and the topside veneer; and a balancing layer arranged on a bottom side of the substrate, wherein the floorboard comprises at least one thermosetting resin side border, wherein the at least one thermosetting resin side border is formed by curing a thermosetting resin adhering to at least one outer side surface of the topside veneer.

31. The floorboard according to claim 30, wherein the floorboard comprises connecting means on side borders.

32. The floorboard according to claim 31, wherein the connecting means are formed in the thermosetting resin side border.

33. The floorboard according to claim 30, wherein the substrate is made of a wood material.

34. The floorboard according to claim 30, wherein the substrate is made of solid wood, chipboard, wood fiber material, MDF (Medium Density Fiber Board) or HDF (High Density Fiber Board).

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0052] In the following the application is explained by way of drawings. It is shown in

[0053] FIG. 1 a top view onto a section of a multilayer body prior to the pressing

[0054] FIG. 2 a representation of the multilayer body after the pressing;

[0055] FIG. 3 a top view onto individual floorboards;

[0056] FIG. 4 an enlarged view of the region of the longitudinal side of two neighboring floor boards with corresponding locking means and

[0057] FIG. 5 again an enlarged view of the region of the longitudinal side of two neighboring floorboards in a further embodiment.

DETAILED DESCRIPTION

[0058] For producing floorboards according to the application a multilayer body is formed. The multilayer body includes a large area starting carrier plate 1. The starting carrier plate 1 is shown in FIG. 1. The starting carrier plate 1 is configured rectangular. Common starting carrier plates 1 have a length between 2,000 mm to 5,600 mm and a width of 1,200 mm to 2,100 mm. usually the starting carrier plate 1 has a thickness of 4.5 mm to 12 mm. on the topside of the starting carrier plate 1 wood veneers 2, 3 are placed. On the bottom side of the starting carrier plate 1 a balancing layer, which is not shown in FIG. 1, is provided between the starting carrier plate 1 and the wood veneers 2, 3 a resin layer 4 made of resin 5 is provided. The resin 5 or the resin layer 4 is indicated schematically in FIG. 1. The resin layer 4 extends two dimensionally over the starting carrier plate 1.

[0059] Onto the starting carrier plate 1 the individual wood veneers 2, 3 are place as strips. The strips extend over the entire length of the starting carrier plate 1 between the starting carrier plate 1 and the veneers 2, 3 the resin layer 4 of resin 4 is integrated (interposed). The resin is in particular a thermoset synthetic resin. The resin layer 4 can be formed by a resin paper. As an alternative the resin layer 4 is formed by a resin film applied onto the topside of the starting carrier plate 1. The resin layer 4 can also be formed by a resin film applied to the bottom side of the veneers 2, 3.

[0060] The individual veneers 2, 3 are spaced apart by a lateral distance a so that a gap 6 is formed between. the individual veneers 2, 3. As mentioned, on the bottom side of the starting carrier plate 1 the balancing layer is arranged. A balancing layer 7 is shown in FIGS. 4 and 5. The starting carrier plate 1 with the placed veneers 2, 3 and the interposed resin layer 4 and the balancing layer 7 form the multilayer body. The multilayer body is placed in a pressing tool where it is pressed. The pressing pressure is greater or equal to 1,000 KPa preferably greater or equal to 3,500 KPa. The pressing temperature is greater than or equal to 100° C., in particular greater than or equal to 120° C. preferably the pressing temperature is between 180° C. and 210° C. the pressing time can be between 10 and 60 seconds.

[0061] FIG. 1 shows the multilayer body prior to the pressing. FIG. 2 shows the multilayer body after the pressing. During the pressing of the multilayer body the resin 5 of the resin layer 4 is plasticized under the influence of heat and cured. By means of the resin 5 the starting carrier plate 1 and the wood veneers 2, 3 are glued to each other. Further the gaps 6 between the veneers 2, 3 are filled with resin 5. Moreover, the resin infiltrates the wood veneers 2, 3. The resin permeates the veneers 2, 3 up to their topside or surface 8. As a result, pores, cracks, gaps and/or other flaws in the veneers 2, 3 are filled with resin 5. The veneers 2, 3 are permeated with resin 5 so that after the pressing resin 5 is visible at the surface 8 of the veneers 2, 3.

[0062] After the pressing the pressed multilayer body is separated into individual floorboards 9, 10. Individual floorboards 9, 10 are shown in FIG. 3. The separation of the multilayer body into individual floorboards 9, 10 is performed in the region of a respective gap 6 between two neighboring veneers 2, 3. As an example two separation lines T1, T2 are indicated in FIG. 2 which extend over the length of the starting carrier plate 1 respectively along a gap 6 that is filled with cured resin 5.

[0063] In a subsequent work step the side borders 11, 12 of the floorboards 9, 10 are profiled. During the profiling the side borders 11, 12 are provided with joining means 13, 14. Joining means 13, 14 can be recognized in FIGS. 4 and 5. During the profiling the remainder of the border strip 15, which extends along a floorboard 9, 10 as border strip 15, 16 of resin 5, can be completely removed. It is also possible that a border strip 15, 16 of resin 5 remains along the side borders 11, 12 of the veneers 2, 3.

[0064] The resin 5 can also be enriched with a filler. The surface of the floorboards 9, 10 can also be printed with a decor. Also, the side borders 11, 12 or the border strips 15, 16, which are made of hard resin material, can be printed. The surface of the floorboards 9, 10 can be provided with a sealing. Furthermore, the surface of the floorboards 9, 10 can be subjected to a mechanical surface processing, in particular a grinding process and/or a brushing process and/or an embossing process. The aforementioned measures serve for optically accentuating and texturizing the surface.

[0065] FIGS. 4 and 5 schematically illustrate the construction of the floorboards 9, 10 produced according to the application in their vertical plane. The Figures are not to be understood to be to scale.

[0066] Each floorboard 9, 10 has a carrier plate V, on the topside of which a veneer 2 or 3, i.e., a wood veneer is applied. The carrier plate V and the wood veneer 2, 3 are pressed and glued to each other via a resin layer 4 or resin. 5 over their entire surface. On the bottom side of the carrier plate V the balancing layer 7 is provided. At the side borders 11, 12 of the floorboards 9, 10 connecting means 13, 14 are provided in the form of locking strips. In a floor cover of neighboring floorboards 9, 10 the respective corresponding locking strips engage with each other. In FIGS. 4 and 5 the locking strips are shown at two opposing longitudinal sides of the floorboards 9, 10. The floorboards 9, 10 also have locking means at their respective head sides, which however are not shown here.

[0067] The carrier plate V and the topside wood veneer 2, 3 and the carrier plate V and the bottom side balancing layer 7 are thermally pressed with each other and inseparably glued with each other. The gluing between the carrier plate V and the wood veneer 2, 3 is accomplished via the interposed resin 5. Also, the balancing layer 7 is glued with the carrier plate V via a resin 5.

[0068] The floorboards 9, 10 are produced as described above. The individual floorboards 9, 10 are separated from the pressed multilayer body. Hereby the multilayer body is separated along the gaps 6 which extend over the entire length.

[0069] As can be seen in FIG. 4, in the floorboard 9 a border strip 16 made of resin 5 or a residual gap that had remained after profiling of eh side borders 11, 12 after the separation was removed. Wood veneer 2 and resin layer 4 end flush with the upper face side 17 of the side borders 11, 12.

[0070] In the floorboard 10 as shown in FIG. 5, a border strip 15, 16 is formed at the side borders 11, 12 of the wood veneer 3. Thus, border strips 15, 15 are made of resin 5. The surface 18 of the border strips 15, 16 extends in the plane of the surface 8 of the wood veneer 3.

[0071] As mentioned above during the production of the floorboards 9, 10 the starting carrier plate 1 or the carrier plate V, the wood veneer 2, 3 the balancing layer 7 with the interposed resin 5 are pressed to each other under heat influence. During the pressing procedure the resin 5 is plasticized. The resin 5 present between the starting carrier plate 1 and the wood veneer 2, 3 infiltrates the wood veneer 2, 3. Hereby the resin 5 can permeate the wood veneer 2, 3 up to the surface 8 of the wood veneer 2, 3. Pores, cracks, gaps, or other flaws in the wood veneer are filled with resin 5 during the pressing. A subsequent gluing of the wood veneer 2, 3 with the starting carrier plate 1 follows and the smoothening of the surface 8 of the wood veneer 2, 3 together in one work step during pressing of the multiplayer body.

REFERENCE SIGNS

[0072] 1—starting carrier plate

[0073] 1T—carrier plate

[0074] 2—wood veneer

[0075] 3—wood veneer

[0076] 4—resin layer

[0077] 5—resin

[0078] 6—gap

[0079] 7—balancing layer

[0080] 8—surface of 2, 3

[0081] 9—floorboard

[0082] 10—floorboard

[0083] 11—side border

[0084] 12—side border

[0085] 13—joining means

[0086] 14—joining means

[0087] 15—border strip

[0088] 16—border strip

[0089] 17—face side of 11, 12

[0090] 18—surface of 15, 16

[0091] a—distance

[0092] T1—separation line

[0093] T2—separation line