Wall or floor covering element

Abstract

A covering element for walls, floors, ceilings or the outdoor area, including a carrier plate containing a mineral material, which carrier plate carries a polymer-containing decor layer on its front side, which covering element includes complementary recesses and protrusions extending at its lateral edges, wherein the recesses and protrusions are formed respectively on lateral edges facing away from each other, such that they engage each other when covering elements are situated next to each other, which recesses and protrusions are arranged in the carrier plate.

Claims

1. A covering element, the covering element comprising: a carrier plate comprising a mineral material, wherein the carrier plate is formed as a flat mineral carrier plate with a content of cement larger than 35 percent by volume, wherein the carrier plate is multi-layered, wherein the carrier plate carries a polymer-containing decor layer on a front side of the carrier plate, wherein the carrier plate has a thickness between 3 and 15 mm; and complementary recesses and protrusions respectively on opposing lateral edges of the carrier plate of the covering element, such that in an assembled condition of two or more covering elements the complementary recesses and protrusions engage with each other, wherein an uppermost layer of the carrier plate is reinforced, at least at the opposing lateral edges comprising the recesses, by a portion of a polymer contained in the polymer-containing decor layer that penetrates into the uppermost layer over a depth greater than 0.1 millimeter.

2. The covering element of claim 1, wherein the decor layer comprises at least one, color pigment-containing, base layer on the carrier plate, wherein on the base layer at least one color pigment-containing digital printing layer is arranged, wherein on the digital printing layer at least one polymer-containing transparent top layer is arranged, the polymer-containing transparent top layer having a textured surface.

3. The covering element of claim 2, wherein the polymer containing transparent top layer contains PUR or acrylic.

4. The covering element of claim 2, wherein the polymer-containing transparent top layer contains a UV-hardening polymer, the polymer-containing top layer, after being applied, being deformed on the outer surface by a structured roller.

5. The covering element of claim 1, wherein the decor layer comprises a mixed layer of a polymer binding material and a filler, wherein the mixed layer is on the carrier plate in liquid condition.

6. The covering element of claim 5, wherein the filler comprises cork or leather particles.

7. The covering element of claim 5, wherein a surface of the mixed layer is structured.

8. The covering element of claim 1, wherein the carrier plate comprises mineral elements pressed together with synthetic or natural fibers, wherein the synthetic fibers have a percentage by volume of 1 to 40%.

9. The covering element of claim 1, wherein the carrier plate is a multi-layered fiber cement board.

10. The covering element of claim 1, wherein the carrier plate has an insulating layer that is an elastomer layer on a rear side of the carrier plate.

11. A method for manufacturing a covering element, the method comprising: providing a carrier plate comprising a mineral material, wherein the carrier plate is formed as a flat mineral carrier plate with a content of cement larger than 35 percent by volume, wherein the carrier plate has a thickness between 3 and 15 mm; coating the carrier plate with a decor layer; and prior to or after providing the decor layer, on opposite lateral edges of the carrier plate, milling respectively recesses and protrusions for a tongue/groove connection, wherein the decor layer is a polymer-containing decor layer, wherein at least a part of the polymer-containing decor layer is applied in liquid form, and wherein a polymer contained in the polymer-containing decor layer penetrates into an uppermost layer of the carrier plate over a depth greater than 0.1 millimeter, at least at the opposite lateral edges comprising the recesses.

12. The method of claim 11, wherein the carrier plate is coated with at least one base layer, which comprises a color pigment-containing, polymer material, wherein onto the base layer, after drying, at least partially at least one color pigment-containing digital printing layer is provided by digital printing, wherein onto the color pigment-containing digital printing layer after drying, hardening, respectively, at least one polymer-containing transparent top layer is provided with a temperature above an ambient temperature, wherein on the top layer, at an increased temperature above the ambient temperature, a surface structure is provided by embossing with at least one structured embossing roller.

13. The method of claim 12, wherein the top layer is provided at a temperature of 40 to 100 degrees Centigrade and treatment of a surface thereof is performed with a structured roller at a temperature of 40 to 100 degrees Centigrade.

14. The method of claim 11, wherein on the carrier plate a hardening decor layer is provided in liquid form and is hardened, wherein the decor layer is a mixed layer of a hardenable polymer, in particular elastomer, and at least one filler.

15. The method of claim 14, wherein the mixed layer is hardened to a modulus of elasticity of 0.03 to 0.5 GPa.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The invention is described below by way of example by the schematic drawing, wherein:

(2) FIG. 1 shows a cross-section through a first covering element, which comprises a decor layer in the digital printing method; and

(3) FIG. 2 shows a cross-section according to FIG. 2 of a second covering element, which comprises a mineral carrier plate with a mixed layer applied in liquid or solid form.

DETAILED DESCRIPTION

(4) FIG. 1 shows a plate-shaped covering element 10, which, with other covering elements 10, can be composed in a planar manner to a floor covering, ceiling covering and/or wall covering, for outdoor use as well. The covering element 10 contains a mineral-containing carrier plate 12, which, at its lateral edges 17, 19 facing away from each other, comprises either protrusions 14 or recesses 16, which, with covering elements situated next to each other, form mating tongue/groove connections. So, in covering elements 10 situated next to each other, the protrusions 14 of one covering element 10 engage the recess 16 of the adjacent covering element 10. Optionally, an insulation layer 18 can be arranged on the rear side, underside, respectively, of the carrier plate 12 for footfall sound insulation and/or thermal insulation. This layer preferably is provided directly on the carrier plate 12 or glued thereon.

(5) On the front side, upper side, respectively, of the carrier plate 12 there is first of all a basic layer 20, which comprises color pigments in order to give the front side, upper side, respectively, of the carrier plate 12 a desired basic color. This basic layer preferably is optional, because basically, with a corresponding choice of the material of the carrier plate 12, the color of the carrier plate can be suitable as a basis for a subsequent digital printing method. A digital print layer 22 is provided on the basic layer 20 in a digital printing method, wherein this digital print layer 22 may be provided not over the entire surface, but only in the areas to be printed. Onto this digital print layer, basic layer 20, respectively, at least one top layer 24 is provided, which in particular consists of a UV-hardening polyurethane or acrylic. A structure 26 is provided on this top layer 24 by an embossing roller, in particular by the hot coating method, which structure preferably reinforces the impression created by the digital print layer 22. In this manner, a covering board is created, which reflects the impression of a desired material very well, for example, a wood layer, a leather layer, a stone layer or a cork layer.

(6) The top layer 24 can also be formed by a plurality of layers of an in particular UV-hardening polymer. The application of the top layer 24 and the profiling thereof preferably is performed in the hot coating method by means of a hot roller. The hot coating method is known as such.

(7) FIG. 2 shows an alternative embodiment of a covering element, wherein identical or functionally identical parts in respect to FIG. 1 are provided with the same reference numerals. The floor covering element 30 from FIG. 2 also comprises a carrier plate 12, which is mineral-containing and comprises protrusions 14 and recesses 16 on lateral edges 17, 19 facing away from each other. The protrusions and recesses of this tongue/groove system are shown only schematically. In practice, the protrusions 14 and recesses 16 are manufactured as described in document EP 0843763, which document hereby is made subject of the present application. In this context, it should be clarified that a covering element of the invention usually is rectangular, in particular square, and that the recesses and protrusions are formed on four sides, wherein the recesses 16 preferably are arranged on two sides situated next to each other and the protrusions 14 on the other two sides situated next to each other.

(8) On the rear side or underside thereof, the mineral carrier plate 12 optionally comprises an insulation layer 18, as already known from FIG. 1. This insulation layer is optional and only necessary if a desired footfall sound insulation and/or thermal insulation are desired. Moreover, this insulation layer, if required, can also be applied as a counterbalancing backing layer. On its upper side, the carrier plate 12 comprises a mixed layer 32 of a polymer and a filler. As a filler, for example, leather, cork, wood, stone, mineral powders, sand are suitable, wherein these materials can be provided in the polymer matrix of the mixed layer either as particles or as fibers. The mixed layer preferably is an elastomer layer, which in particular hardens to a modulus of elasticity of 0.05-0.5 GPa, by which it achieves a rubber-like elasticity. In this manner, for example, an impression of cork, wood or leather can be pronounced very well. Such covering element is very suitable as a wall covering element.

(9) The invention is not limited to the represented exemplary embodiments but can be varied at choice within the scope of protection of the accompanying claims.

REFERENCE NUMERAL LIST

(10) 10 Wall, ceiling or floor covering element (first embodiment) 12 mineral carrier plate 14 protrusiontongue of the tongue/groove connection 16 recessgroove of the tongue/groove connection 17 first lateral edge 18 insulation layer 19 second lateral edge 20 basic layerprimercoupling agent 22 digital printing layer 24 transparent top layer 30 wall, ceiling or floor covering element (second embodiment) 32 mixed layer, in particular applied in liquid form 34 optionally structured surface, in particular by embossing roller