Method for manufacturing a plate shaped product and plate shaped product manufactured thereby

Abstract

A method is presented for manufacturing a plate shaped product, comprising the steps of manufacturing a first intermediate product which comprises at least, successively, a carrier, a plastic printing layer, a decorative print layer and a plastic protective layer, by using a multiple coating process, manufacturing a second intermediate product which comprises at least one plastic layer, by using at least a calendering process, and combining the first and second intermediate products by laminating, such that the second intermediate product is attached to the first intermediate product. Further a plate shaped product is provided which is manufactured using said method.

Claims

1. A plate shaped product comprising: a first intermediate product which comprises, successively, a first carrier, a foam layer, a decorative print layer and a plastic protective layer each coated one on top of the other, and a second intermediate product attached to the first intermediate product, the second intermediate product comprising two compacted backing layers laminated at opposite sides of a second carrier, wherein the first carrier in the first intermediate product is a non-woven glass fiber carrier and the second carrier in the second intermediate product is a woven or non-woven carrier.

2. The plate shaped product according to claim 1, further comprising a plastic backing layer at a side of the first carrier opposite the foam layer.

3. The plate shaped product according to claim 1, wherein the two compacted backing layers laminated at opposite sides of the second carrier have a different composition and/or thickness.

4. The plate shaped product according to claim 1, wherein the two compacted backing layers laminated at opposite sides of the second carrier have a same composition and/or thickness.

5. The plate shaped product according to claim 1, wherein the second intermediate product further comprises at least one foil.

6. The plate shaped product according to claim 1, wherein a slip resistant coating or an adhesive coating covered with a release foil is provided on a side of the second intermediate product facing away from the first intermediate product.

7. The plate shaped product according to claim 1, having a shape of a floor tile or a floor plank.

8. The plate shaped product according to claim 1, having a roll form.

9. The plate shaped product according to claim 1, wherein the plastic protective layer of the first intermediate product has an embossed surface structure.

10. The plate shaped product according to claim 2, wherein the plastic backing layer of the first intermediate product has an embossed surface structure.

11. The plate shaped product according to claim 2, wherein both the plastic protective layer and the plastic backing layer of the first intermediate product have a gelled surface structure.

12. The plate shaped product according to claim 1, wherein a foil is laminated on top of the decorative print layer.

13. The plate shaped product according to claim 1, wherein the first carrier of the first intermediate product is impregnated with a plastic material.

14. The plate shaped product according to claim 1, wherein the plate shaped product further comprises a protective lacquer layer on top of the plastic protective layer.

15. The plate shaped product according to claim 1, wherein the plate shaped product further comprises edge groove and/or connector provisions.

16. A plate shaped product comprising: a first intermediate product which comprises at least, successively, a first carrier, a foam layer, a decorative print layer and a plastic protective layer each coated one on top of the other, and a second intermediate product attached to the first intermediate product, which plate shaped product is manufactured using a method comprising: manufacturing a first intermediate product which comprises at least, successively, the first carrier, the foam layer, the decorative print layer and the plastic protective layer, by using a multiple coating process; compacting two backing layers using a calendaring process to create two calendered, compacted backing layers; laminating the two calendered, compacted backing layers at opposites sides of a second carrier to create the second intermediate product, wherein the first carrier in the first intermediate product is a non-woven glass fiber carrier and the second carrier in the second intermediate product is a woven or non-woven carrier; and combining the first and second intermediate products by laminating, such that the second intermediate product is attached to the first intermediate product.

17. The plate shaped product according to claim 16, the first intermediate product further comprising a plastic backing layer at the side of the first carrier opposite the foam layer.

18. The plate shaped product according to claim 17, wherein the second carrier in the second intermediate product is based on a glass fiber material.

Description

BRIEF DESCRIPTION OF THE DRAWING

(1) Hereinafter the invention will be elucidated while referring to the drawing.

(2) FIG. 1 shows a schematic cross section of an embodiment of a plate shaped product embodied as a floor product in accordance with the present invention.

DETAILED DESCRIPTION

(3) Referring to the drawing, an embodiment of a floor product in accordance with the present invention is illustrated in a schematic cross section (it is noted that this cross section is not necessarily to scale and that the relative dimensions of its constitutive parts may differ from what has been illustrated). This floor product comprises a first upper intermediate product 1 and a lower second intermediate product 2 manufactured separately and thereafter joined together in manners to be described hereafter.

(4) In the illustrated embodiment the first upper intermediate product 1 comprises, successively, a PVC plastisol backing layer 3, a non woven glass fiber carrier 4, a PVC plastisol printing layer 5, a decorative print layer 6 and a PVC plastisol protective layer 7. These layers are positioned one on top of the other using a multiple coating process. Each layer has its specific composition, thickness, weight and function in the final floor product. The most important constituents of the plastisols are PVC, fillers, plasticizers, viscosity controllers, stabilisers and foaming means.

(5) A first step for manufacturing the first intermediate product 1 may comprise impregnating a glass fiber carrier 4 with a first PVC paste. Next the impregnated carrier is transported over a heated roller for pre-gelling (harden) the liquid paste. As a next step the printing layer 5 is coated on top of the impregnated carrier 4. The printing layer 5, which will define the basis for the decorative print layer 6, may comprise a white foam layer.

(6) On top of the printing layer 5 the decorative print layer 6 is provided, e.g. by an appropriate printing technique (such as rotative engraved printing). The used inks may comprise an inhibitor inhibiting the foaming of the printing layer for locally creating a relief (such as a seam in a tile shaped floor product). Finally the protective layer 7 will be coated on top of the decorative print layer 6. Mostly the protective layer 7 will be a transparent PVC layer which offers the floor product important mechanical properties.

(7) Preferably, for manufacturing the protective layer 7 of the first intermediate product 1 a thermic cross linking process is used during a gelling process. As a result a very hard protective wear layer may be obtained. This may be an important requirement for a floor product (e.g. a floor tile). According to such a thermic cross linking part of the plasticizers normally present in the wear layer are substituted by reactive methacrylates and an intiator. Latter will be activated at high temperature and initiates a cross linking. Apart from the gelling process during which the plasticizers diffuse into the plastic (PVC) grains and cause the wear layer to harden, an additional cross linking between the methacrylates among themselves and between the methacrylates and the PVC chains occurs. This results in a wear layer (protective layer) which is very hard.

(8) Additionally decorative particles may be dispersed into the protective layer 7.

(9) It is possible to pre-gel the PVC plastisols in the printing layer 5 and protective layer 7 by a heated roller. Also the carrier 4 may be pre-gelled.

(10) Next the backing layer 3 may be coated to the impregnated carrier 4, for example using a foaming technique (e.g. chemically or mechanically, as is known per se). This backing layer 3 offers the final floor product the required comfort (resilience and damping).

(11) Next the intermediate product 1 is placed in a hot air furnace (heated to for example 205 C.) for a few minutes and a complete gelling and foaming will occur. After cooling the floor product a laquer layer (not illustrated) may be applied on top of the protective layer 7. As an alternative the laquer layer is applied previously to gelling.

(12) Finally the protective layer 7 and the backing layer 3 may be provided with a surface structure (for example by mechanically embossing).

(13) The obtained first intermediate product 1 may be finished (among others by cutting it to size, removing edges) and may be stored until later laminating with the second intermediate product 2.

(14) The second intermediate product 2 is not manufactured by coating techniques but by calendaring (and possibly laminating) processes using, among others, calendering (and laminating) rolls. In an exemplary embodiment of such calendaring processes firstly compounds based on PVC, mineral or organic fillers, plasticizers, additives and colorants are produced which are fed to an extruder. In the extruder a homogenisation and melting of the compound occurs. The extruded material is fed to the calendering rolls for producing PVC foils.

(15) In the illustrated embodiment the second intermediate product 2 comprises a first compact calendered backing layer 8, a carrier 9 (which may be precoated, e.g. with a plastisol, for enhancing the adhesion with the calandered layers) and a second compact calendered backing layer 10. Each of the backings 8 and 10 may comprise several separately calendered layers (foils, but also foam layers), if required (for example for achieving a required minimal thickness) laminated together. The carrier 9 may comprise a woven or non woven carrier which may be based on glass fiber material.

(16) The carrier 9 is fed to one or more laminating rolls, together with the backing layers 8 and 10 and the layers are laminated for obtaining the second intermediate product 2. It is possible to pre-heat the backing layers and/or carrier to improve the lamination, e.g. using infrared lights or heated rolls.

(17) Once the first and second intermediate products 1 and 2 have been manufactured, these products are joined by a further lamination process for obtaining the final floor product. If necessary, finishing steps may be carried out (among which embossing the upper and lower side of the final product, cutting the product to size and the provision of connector provisions).

(18) The invention is not limited to the embodiments described before which may be varied widely within the scope of the invention as defined by the appending claims.