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

Abstract

Provided a method for manufacturing 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 decorative layer to the at least one plastic carrier plate; applying at least one primer layer to the at least one decorative layer; and uniformly scattering abrasion-resistant particles onto the at least one primer layer applied to the decorative layer applying at least one cover layer.

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 decorative layer to the at least one plastic carrier plate; application of at least one primer layer to the at least one decorative layer; uniform scattering of abrasion-resistant particles onto the at least one primer layer applied to the decorative layer; and applying at least one cover layer.

2. The method according to claim 1, wherein the plastic carrier plate is provided as a continuous strand and is cut to size after coating.

3. The method method according to claim 1, wherein the plastic carrier plate is produced by extrusion of a mixture comprising PVC, limestone and optional auxiliary materials.

4. The method according to claim 3, wherein the mixture to be extruded contains 20-40 wt % PVC, preferably 25-35 wt % PVC, 60-80 wt % limestone, preferably 65-75 wt % limestone, and optionally other auxiliaries.

5. The method according to claim 1, wherein a decorative film, in particular a PVC decorative film, is applied as the decorative layer to the plastic carrier plate, in particular by calendering.

6. The method according to claim 1, wherein at least one primer layer is applied to the decorative film.

7. The method according to claim 1, wherein the primer layer comprises polyurethane.

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

9. The method according to claim 1, wherein a cover film, in particular a transparent PVC cover film, is applied as cover layer, in particular calendered on.

10. The method according to claim 9, wherein, at least one lacquer layer, in particular at least one polyurethane lacquer layer, is applied to the cover film to improve the scratch resistance and to adjust the gloss level.

11. The method according to claim 1, wherein a lacquer structure comprising at least one lacquer layer and at least one top lacquer is applied as a covering layer.

12. The method according to claim 1, wherein a structure is introduced into the cover layer using a structure-imparting roller or a mechanical pressing element (pressing device).

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

14. 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 decorative layer on the at least one plastic carrier plate; at least one primer layer on the at least one decorative layer; at least one layer of abrasion resistant particles on the at least one primer layer; and at least one cover layer, wherein the at least one plastic carrier plate and the layers applied thereto are bonded together by means of calendering.

15. A production line for carrying out a method according claim 1 comprising at least one extruder device for providing a plastic carrier plate, in particular in the form of a continuous strand; at least one device for applying at least one decorative layer to the at least one plastic carrier plate; at least one device for scattering a predetermined amount of abrasion-resistant particles, arranged downstream of the at least one device for applying at least one decorative layer; and at least one device arranged downstream of the spreading device in the processing direction for applying at least one covering layer to the spread abrasion-resistant particles.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0101] The solution is explained in more detail below with reference to the figures in the drawings, using an example of an embodiment.

[0102] FIG. 1 shows a schematic representation of a production line of a multilayer panel according to a first embodiment of the method according to the solution

[0103] FIG. 2 shows a schematic representation of a production line of a multilayer panel according to a second embodiment of the method according to the solution.

DESCRIPTION OF THE INVENTION

[0104] The production line shown schematically in FIG. 1 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.

[0105] 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.

[0106] 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.

[0107] 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 for further processing.

[0108] Downstream of extruder 15 in the processing direction is a device for applying a decorative PVC film. This device comprises a roll 16a, via which the PVC decorative film is fed online, and a calendering roll 16b, via which the PVC decorative film is calendered onto the still warm continuous strand.

[0109] Downstream of the application device 16a, 16b for the PVC decorative film, a first scattering device 17 is provided for uniformly scattering the abrasion-resistant material such as corundum onto the decorative film 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.

[0110] The spreading device 17 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 EN 13329)=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 film.

[0111] The spreading device 17 is followed in the processing direction by the device for applying a transparent PVC film as a cover layer. This device also comprises a roll 18a, via which the transparent PVC cover film is fed online, and a calendering roll 18b, via which the transparent PVC cover film is calendered on. The calendering roll 18b used is temperature-controlled and designed as a structure roll, so that simultaneous structuring and calendering of the PVC cover film is possible.

[0112] If a lacquer structure is used as a cover layer, the lacquer layer(s) is/are applied using an applicator unit. The applicator is followed in the processing direction by devices for curing the lacquer structure, in particular ESH emitters and excimer emitters (not shown).

[0113] Suitable cooling devices and cutting device in are provided for further fabrication (not shown).

[0114] In addition to the elements and devices shown in FIG. 1 and described above, the production line shown in FIG. 2 comprises an applicator 19 for applying a PU primer layer to the PVC decorative film. The applicator 19 is provided downstream of the device for applying the PVC decorative film and can be designed as a roller applicator or spray unit.

EXAMPLE 1

[0115] A compound consisting of approx. 65 wt % chalk and 35 wt % PVC was melted at approx. 140° C. in an extruder. The compound contained the usual auxiliaries, such as lubricants, antioxidants, etc. The compound was pressed through a profile with the dimensions 1300×4 mm with simultaneous cooling.

[0116] Then, in a first step, a decorative film was calendered on. This was a PVC film (approx. 80 g/m.sup.2 basis weight) printed with a wood decor.

[0117] A corundum modified with an oligomeric alkyl silane (15 g corundum/m.sup.2, grain size: F 220) was then scattered onto this with the aid of a spreader. A transparent PVC film (basis weight: 50 g/m.sup.2) was calendered onto this.

[0118] For comparison, a sample was produced without corundum but with a transparent PVC film (basis weight: 96 g/m.sup.2).

[0119] Both transparent films were structured by a structured calendering roll during calendering. The continuous strand is then cut to size. A PU coating (30 g coating/m.sup.2) or UV coating was still applied to both samples to improve scratch resistance and cured.

[0120] The abrasion resistance of both samples was then tested in accordance with DIN EN 13329, Appendix E. Both samples achieved service class 34 (>4000 um).

EXAMPLE 2

[0121] A compound consisting of approx. 65 wt % chalk and 35 wt % PVC was melted at approx. 140° C. in an extruder. The compound contained the usual auxiliaries, such as lubricants, antioxidants, etc. The compound was pressed through a profile with the dimensions 1300×4 mm with simultaneous cooling.

[0122] Then, in a first step, a decorative film was calendered on. This was a PVC film (approx. 80 g/m.sup.2 basis weight) printed with a wood decor.

[0123] A PU-based primer (approx. 15 g/m.sup.2, liquid) was then rolled or sprayed onto the decorative film.

[0124] A corundum modified with an oligomeric alkyl silane (15 g corundum/m.sup.2, grain size: F 220) was then scattered onto this with the aid of a spreader. A transparent PVC cover film (basis weight: 50 g/m.sup.2) was calendered onto this.

[0125] For comparison, a sample was produced without primer and corundum, but with a transparent PVC film (basis weight: 96 g/m.sup.2).

[0126] Both transparent films were structured by a structured calendering roll during calendering. The continuous strand is then cut to size. A PU coating (30 g coating/m.sup.2) or UV coating was still applied to both samples to improve scratch resistance and cured.

[0127] The abrasion resistance of both samples was then tested in accordance with DIN EN 13329, Appendix E. Both samples achieved service class 34 (>4000 um).

EXAMPLE 3

[0128] A compound consisting of approx. 65 wt % chalk and 35 wt % PVC was melted at approx. 140° C. in an extruder. The compound contained the usual auxiliaries, such as lubricants, antioxidants, etc. The compound was pressed through a profile with the dimensions 1300×4 mm with simultaneous cooling.

[0129] Then, in a first step, a decorative film was calendered on. This was a PVC film (approx. 80 g/m.sup.2 basis weight) printed with a wood decor.

[0130] A PU-based primer (approx. 15 g/m.sup.2, liquid) was then rolled or sprayed onto the film. Corundum modified with a methacrylic silane was then sprinkled into the primer with the aid of a spreader (15 g corundum /m.sup.2, grain size: F 220).

[0131] The continuous strand is then either cut to size or further processed as a continuous strand. A coating structure consisting of an ESH coating (60 g/m.sup.2) and a UV-based top coat to improve scratch resistance (20 g/m.sup.2) was applied to the surface. The first lacquer was pre-gelled with an ESH radiator. The top lacuer was pre-cured with an excimer emitter, resulting in a matte finish (<5 gloss points). The entire build-up was then cured with an ESH emitter.

[0132] For comparison, a sample was produced with a primer, an ESH coating (120 g/m.sup.2) and a topcoat to improve scratch resistance, also UV-based (20 g/m.sup.2). The first UV coating was annealed with an ESH lamp and then the topcoat was applied. This was cured with an excimer emitter, producing a matte surface (<5 gloss points). The entire structure was then cured with an ESH lamp.

[0133] Both samples were then tested for abrasion resistance according to DIN EN 15468: 2013 Annex A. Both samples achieved service class 34 (>7000 um).

[0134] Of course, other types of film can also be used to cover the corundum particles, such as PET, PU, etc. In addition to a coating, a hotcoating application can also be used for covering.