Method and installation for manufacturing a floor covering product and floor covering product obtained hereby

Abstract

A method for manufacturing a floor covering product includes the steps of forming a single- or multilayered substrate by extruding of synthetic material-based material in a layer shape; laminating at least one continuous film to the substrate; and impressing the at least one continuous film using a roller provided with a relief on its surface.

Claims

1. A method for manufacturing a floor covering product, said method comprising the steps of: forming a single- or multilayered substrate by extruding of synthetic material-based material in a layer shape; laminating at least one continuous film to said substrate; impressing said at least one continuous film using a roller being provided with a relief on its surface; wherein the substrate and said at least one continuous film form a material web, and that this material web is bent around said roller as the at least one continuous film is impressed by the roller, the substrate being located radially away from the relief of the roller and the continuous film being radially closer to and facing the relief, such that the cooperation between the relief and the at least one continuous film takes place at least over an arc-shaped part; wherein at least the continuous film, when bent around said roller, is subjected to bending having a radius of 40 cm or more; wherein said at least one continuous film comprises a decor layer and that this film, prior to laminating, is subjected to controlled stretching in order to stretch the decor to a greater or lesser extent, in the width and/or length, such that the decor is adjusted in function of the desired final result.

2. The method according to claim 1, wherein the synthetic material is selected from following materials consisting the group of: polyvinyl chloride (PVC), polypropylene (PP), polyethylene (PET) and polyurethane (PUR).

3. The method according to claim 1, wherein the at least one continuous film comprises a printed film.

4. The method according to claim 3, wherein the impressions are in register with the décor.

5. The method according to claim 1, wherein the roller is applied with, seen along the circumference, at least two segments, which each are provided with a relief, wherein in circumferential direction the distance between at least two of these segments is adjustable in order to change the “repeat” with which the impressions are realized.

6. The method according to claim 1, wherein the material, which is moving along with the roller, of the material web is maintained in contact with the roller at least for 3 seconds.

7. The method according to claim 1, wherein the material web is supplied to the roller in a heated condition and that the roller is cooled.

8. The method according to claim 1, wherein the floor covering product is provided with a translucent wear layer.

9. The method according to claim 1, wherein the substrate is a multilayered substrate.

10. The method according to claim 1, wherein the continuous film has one or more of the following characteristics: a thermoplastic synthetic material film; a PVC film, PU film, PP film, or PET film; an oriented polypropylene film; and a hard PVC film on the basis of PVC without plasticizer or with an amount of plasticizer of less than 5 percent by weight.

11. The method according to claim 1, wherein the impressions are provided in the upper side of the floor covering product in the same continuous process after laminating the continuous film onto the substrate.

12. The method according to claim 1, wherein the lamination is applied by a belt press.

13. The method accordingly to claim 1, wherein the continuous film is directly adjacent the relief of the roller.

14. A method for manufacturing a floor covering product, said method comprising the steps of: forming a single- or multilayered substrate by extruding of synthetic material-based material in a layer shape; laminating at least one continuous film to said substrate; impressing said at least one continuous film using a roller being provided with a relief on its surface; wherein at least the continuous film is bent around said roller with the continuous film facing the relief, such that the cooperation between the relief and the continuous film takes place at least over an arc-shaped part; wherein the substrate and said continuous film form a material web, and that this material web is bent around said roller as the continuous film is impressed by the roller, the substrate being located radially away from the relief of the roller and the continuous film being radially closer to the relief; wherein the material, which is moving along with the roller, of the material web is maintained in contact with the roller at least for 3 seconds; and wherein at least the continuous film, when bent around said roller, is subjected to bending having a radius of 40 cm or more.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) With the intention of better showing the characteristics of the invention, herein below, as an example without any limitative character, some preferred embodiments are described, with reference to the accompanying drawings, wherein:

(2) FIG. 1 schematically illustrates a possible embodiment of the method of the invention, as well as schematically represents the installation applied therewith;

(3) FIG. 2 represents a variant.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS OF THE INVENTION

(4) In the accompanying FIG. 1, an installation 1 according to the invention is represented, which consists at least of a device 2 for forming a substrate 3 by consolidation of synthetic material-based starting material 4, as well as a subsequent device 5 for laminating at least one preferably continuous film 6 on the substrate 3, wherein this last-mentioned device 5, for the lamination makes use of a belt press 7, such that the film 6 is pressed, at least over a well-defined distance, in contact with the substrate 3.

(5) The device 2 preferably is of the type wherein the substrate is formed by means of a strewing process, wherein the synthetic material-based starting material 4 is strewn as a granulate in a strewing portion 8 of the device 2 and subsequently is consolidated in a press device or press portion 9. As represented schematically, this press portion 9 preferably consists of a double-belt press 10.

(6) The strewing portion 8 may be of a different construction and possibly may also comprise supply means 11 for incorporating a reinforcement layer, such as a glass fiber fleece 12, into the substrate.

(7) As aforementioned and according to the first aspect of the invention, the device 5 comprises a belt press 7. In particular, it is preferred that this belt press 7 is made as an isobaric press, wherein laminating the continuous film 6 in the belt press is performed by means of a fluid pressure P, which is exerted on a surface 13 of a belt 14 of the belt press 7. As represented schematically, to this aim a chamber 15 may be formed along this belt, which chamber is bordered by a frame or border 16, wherein in the thus formed chamber 15 a pressure can be built up, which pressure acts on the respective portion of the belt 14.

(8) In this manner, a uniform pressure is realized during laminating, by which a smooth lamination is created.

(9) It is clear that the belt press 7 preferably is a double-belt press having a second belt 17 which provides for the necessary support.

(10) The use of an isobaric press shows the advantage that on the location where the actual lamination is performed, a very uniform compression takes place, by which stresses in the plane of the substrate and the film practically are excluded, which leads to a uniform lamination

(11) It is represented schematically that also still another film 18 can be laminated along. In a practical embodiment, the film 6 will be intended for forming a decor layer, whereas the film 18 forms a wear layer. It is noted that it is not excluded to laminate, according a not-represented embodiment, the films 6 and 18 each by means of an own belt press 7, wherein then two belt presses 7 have to be installed one after the other.

(12) It is noted that according to a not-represented variant, it is not excluded to apply an isobaric press, wherein the fluid presses directly on the respective film or films, without the intermediary of a belt or any other element.

(13) Further, the method applied therewith may comprise also other steps, wherein the necessary devices and/or additional provisions to this aim then are integrated into the installation.

(14) So, for example, according to an important preferred embodiment, the installation is provided with a device 19 for forming impressions in the floor covering product 20 to be formed. As represented in the accompanying figure, to this aim preferably use is made of a roller 21 with along the circumference at least two segments 22-23, which each are provided with a relief 24-25, whether or not the same relief, wherein in circumferential direction the distance A1-A2 between at least two of these segments is adjustable in order to change the so-called “repeat” with which the impressions are realized, wherein this change preferably is performed in function of the position of the decor, this automatically, and with the intention of producing so-called “registered embossed” products.

(15) At the entry of the device 19, a heating device 26, for example, by means of infrared radiation, can be provided for heating the upper side of the respective material layer or material web 27, preferably almost up to melting temperature, in order to obtain that the impressions can be realized. The roller 21 can be cooled in order to consolidate the then realized impressions in the obtained form by the cooling down and stiffening of the material layer 27, the longer this material layer is in contact with the roller over a longer time.

(16) Further, it is also represented schematically in the figure that the installation 1 also can be provided with a device 28 for subjecting the substrate at least on one side to an additional levelling treatment, such as, for example, a grinding machine.

(17) As aforementioned, the film 6 is intended for forming a decor layer. To this aim, this film 6 can be supplied as a printed film from a supply roll 29. According to an alternative, however, printing may also take place on site by means of a device 30, more particularly a printing device and in particular a digital printer or printing unit.

(18) Also, it is not excluded to provide a further device 31 for subjecting the film 6 to a certain stretching, preferably in a controlled manner, for adjusting the length and/or width of the decor, for example, in function of an impression pattern to be provided afterwards.

(19) In this manner, for example, by means of the device 31 an additional adjustment of the width of the decor can be provided for, whereas by means of the device 19 an adjustment of the length is provided by adapting the average so-called “repeat”.

(20) It is noted that it is not excluded to first have the belt press 7 be preceded by one or more pressing rollers, although this preferably shall not be the case.

(21) At the entry of the belt press 7, preferably a heating is provided in order to obtain that the respective film 6 and/of 18 and/or the surface of the substrate is sufficiently heated in order to come to a consolidation by fusing. This heating may be performed by making use, at the entry of the belt press 7, of a heated roller, more particularly a deflection roller 32. However, in the chamber 15 preferably a cooled fluid is applied, for example, cooled air, in order to obtain in this manner a consolidation by stiffening after fusion.

(22) According to an alternative, which may or may not be combined with the heating at the entry of the belt press 7, various temperatures can be maintained in the chamber 15, or the chamber may also be subdivided into segments in which different temperatures are prevailing. For example, on the run-in side a high temperature may be maintained in order to promote fusing, whereas on the exit side cold air can be provided.

(23) Finally, it is noted that in particular in respect to the effect of the strewing process, on the one hand, and in respect to the realization of impressions with an adjustable roller, on the other hand, all information of the following patent applications has to be understood as being incorporated in the present application by reference: WO 2013/179261 BE 2014/0517 PCT/IB2014/058464

(24) In FIG. 2, a variant is represented with the particularity that the reinforcement material, and in particular the reinforcement layer, such as the glass fiber fleece 12, is brought into contact with a plastisol, this in order to obtain a finally better consolidation and adherence among the various layers and to minimize the risk of a later delamination. In the example of FIG. 2, the plastisol is provided on the reinforcement layer, such as the glass fiber fleece 12, by means of a schematically represented device 34, whereby this penetrates in and through the glass fiber fleece and reaches the relatively rough surface of the lowermost strewn layer. In FIG. 2 is also shown that a second layer of starting material 4 is strewn here over. By providing for that the plastisol is gelled, a consolidated whole is obtained with a good mutual adherence. For gelling the plastisol 33, of course the necessary heat has to be supplied. In the represented example, this is realized by means of a heating device 35 installed between the device 34 and the second strewing device. It is noted that the heating may also take place at other locations, for example, downstream of the second strewing device, whether or not in the press portion 9. It is noted that the plastisol possibly may also be supplied to the reinforcement layer 12 before this latter is brought into contact with the strewn starting material.

(25) According to a not represented embodiment, after the application of the reinforcement layer and the plastisol no additional starting material is strewn thereon, such that the plastisol forms the upper layer for the further process. In such case, it is even not excluded to add the reinforcement layer and the plastisol only after the press portion 9 and subsequently guiding or not guiding it through an own press portion.

(26) It is noted that the herein above-mentioned possibilities for using a plastisol as such form independent aspects of the present invention, in particular where and how the plastisol is applied in combination with the strewing. These independent aspects thus may be applied whether or not in combination with the further downstream applied steps which were described herein above. Thus, combinations with other, subsequent production techniques are not excluded.

(27) Finally, it is also noted that it is not excluded to work, instead of with a device 30 for printing the film 6 which is installed at a location before this film 6 is brought into contact with the substrate, with a device which provides a print after the film 6 is laminated onto the substrate, and preferably prior to providing possible prints.

(28) According to a deviating independent aspect of the invention, one or more of the herein above-described production steps, which take place during said strewing, are combined with the application of a print directly on the formed material web, irrespective whether a film 6 is applied or not. As an example, this means that, for example, the film 6 is not provided and there is also no device 5, however, that at that location a printing device for providing a print is present.

(29) It is also noted that, when a transparent lacquer layer is provided, this latter can be provided before or after providing the impressions on the final surface.

(30) The present invention is in no way limited to the herein above-described embodiments, on the contrary may such method and installation be realized according to various variants without exceeding the scope of the present invention. Moreover, the panels, instead as floor panels, may also be made as wall panels or ceiling panels or even as furniture panels. Alternatively, the invention thus also relates to the same method as described herein above, however, then applied for the production of other panels than floor panels.