Method for Producing an Abrasion- and Water-Resistant Multilayer Panel and a Panel Which is Produced Using Said Method

Abstract

It is provided a method for producing an abrasion- and water-resistant multilayer panel, in particular an abrasion- and water-resistant flooring panel, including the steps: providing at least one plastic carrier plate, in particular a PVC carrier plate; applying at least one base coat to the surface of the plastic carrier plate; printing the plastic carrier plate by direct printing to form a decorative layer; applying at least one first cover layer to the printed decorative layer; uniformly scattering abrasion-resistant particles onto the at least one cover layer applied to the decorative layer; applying at least one second covering layer to the layer of scattered abrasion-resistant particles; optionally, introducing a structure into the at least second cover layer, applying at least one lacquer layer, and curing the layer structure.

Claims

1. A method of manufacturing an abrasion and water resistant multilayer panel, in particular an abrasion and water resistant floor panel, comprising the steps of: providing at least one plastic carrier plate, in particular a PVC carrier plate; applying at least one base coat comprising at least one hot melt adhesive to the surface of the plastic carrier plate; direct printing of the plastic carrier plate with the formation of a decorative layer; applying at least one first cover layer comprising at least one hot melt adhesive to the imprinted decorative layer; uniform scattering of abrasion-resistant particles onto the at least one cover layer applied to the decorative layer; applying at least a second cover layer comprising at least one hot melt adhesive to the layer of scattered abrasion resistant particles; optionally, introducing a structure into the at least second cover layer; applying at least one lacquer layer; and curing of the layer structure.

2. The method according to claim 1, wherein the surface of the plastic carrier plate is pretreated before printing to improve the adhesion of the subsequent layers, preferably by means of a grinding operation.

3. The method according to claim 1, wherein the base coat to be applied to the surface of the plastic carrier plate before printing comprises at least one primer layer.

4. The method according to claim 1, wherein at least one white ground is applied to the base coat before printing.

5. The method according to claim 4, wherein the white ground is applied to the base coat by means of digital printing.

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

7. The method according to claim 1, wherein particles of corundum (aluminum oxides), boron carbides, silicon dioxides, silicon carbides are used as abrasion-resistant particles.

8. The method according to claim 1, wherein the at least one lacquer layer comprises a UV top lacquer.

9. The method according to claim 1, wherein a structure is introduced into the at least one top lacquer.

10. The method according to claim 1, wherein a lockable tongue-and-groove joint is introduced at at least two opposite edges of the panel.

11. An abrasion resistant and waterproof multilayer panel producible in a method according to claim 1 comprising: at least one plastic carrier plate, in particular a PVC carrier plate; at least one base coat comprising at least one hot melt adhesive; at least one decorative layer printed by direct printing, at least one first cover layer provided on the decorative layer comprising at least one hot melt adhesive; at least one layer of abrasion resistant particles on the at least one first cover layer; at least one second, preferably structured, cover layer provided on the layer of abrasion-resistant particles, comprising at least one hot-melt adhesive, and at least one lacquer layer provided on the second cover layer.

12. A panel according to claim 11, comprising: at least one plastic carrier plate, in particular a PVC carrier plate; at least one base coat comprising at least one hot melt adhesive, at least one white ground; at least one decorative layer printed directly onto the base coat, at least one first cover layer provided on the decorative layer comprising at least one hot melt adhesive; at least one layer of abrasion resistant particles on the at least one first cover layer; at least one second, optionally structured cover layer provided on the layer of abrasion-resistant particles, comprising at least one hotmelt adhesive, and at least one lacquer layer provided on the second cover layer.

13. A production line for carrying out a method according to claim 1 comprising: at least one device for applying at least one base coat comprising at least one hot melt adhesive to the at least one plastic carrier 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 first cover layer comprising at least one hot-melt adhesive to the decorative layer; at least one device for scattering a predetermined amount of abrasion resistant particles; and at least one device arranged downstream of the scattering device in the processing direction for applying at least one second covering layer comprising at least one hot-melt adhesive, and at least one device for applying a lacquer layer.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0123] The solution is explained in more detail below with reference to the figures in the drawings, using an example of an embodiment.

[0124] FIG. 1 shows a schematic representation of a production line of a multilayer panel according to one embodiment of the method according to the solution.

DESCRIPTION OF THE INVENTION

[0125] 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.

[0126] 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.

[0127] 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.

[0128] 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.

[0129] 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 sheet-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, cut to size and stacked.

[0130] Subsection 2 for the surface treatment of the plastic carrier plate starts with a separation and pre-treatment of the carrier plates, such as grinding (not shown).

[0131] In a next step, at least one white-pigmented PUR hot melt is applied as a base coat to the surface of the plastic carrier plate using a roller unit 20.

[0132] 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.

[0133] The at least one device provided downstream of the printer 22 in the processing direction for applying a hot coating (PUR hot melt) as a first cover layer to the decorative layer is designed as a roller application device 23.

[0134] 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.

[0135] 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.

[0136] The scattering device 24 is followed in the processing direction by the device 25 for applying a hot coating as a second cover layer. Here, too, a PUR hotmelt is used as the hotcoating.

[0137] The final lacquer layer is also applied using a roller device 27.

[0138] A textured roller 26 is provided between the device 25 for applying the second cover layer and the roller device 27 for applying the final lacquer layer.

[0139] 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).