COVERING ELEMENT

Abstract

A covering element for a floor, wall and/or ceiling covering, in particular a laminate covering element, with an upper layer structure, a stability layer of wood and/or of a wood-based material adjoining the rear side of the upper layer structure, an elastic and/or acoustically damping layer adjoining the rear side of the stability layer, and a carrier plate adjoining the rear side of the damping layer.

Claims

1. A covering element for a floor, wall and/or ceiling covering, the covering element having: an upper layer structure; a stability layer of wood and/or of a wood-based material adjoining a rear side of the upper layer structure; an elastic and/or acoustically damping layer adjoining a rear side of the stability layer; and a carrier plate adjoining a rear side of the damping layer.

2. The covering element according to claim 1, wherein the covering element is designed to be PVC-free; and/or wherein the stability layer is free of plastic and/or at least substantially free of plastic, with a plastic content in the material chosen from less than 5% by weight, less than 3% by weight, and less than 1% by weight.

3. The covering element according to claim 1, wherein the carrier plate has connecting geometries on the edge sides, in particular tongue-and-groove connecting geometries of a click connection, for connecting adjacent covering elements.

4. The covering element according to claim 1, wherein the stability layer has a thickness chosen from between 0.3 to 5 mm and between 0.5 to 2 mm; and/or wherein the damping layer has a thickness chosen from between 0.3 and 5 mm and between 0.5 and 2 mm; and/or wherein the carrier plate has a thickness chosen from between 2 to 15 mm, between 4 to 10 mm, and between 6 to 9 mm.

5. The covering element according to claim 1, wherein the upper layer structure has a decorative layer and/or an upper wear layer.

6. The covering element according to claim 1, wherein the upper layer structure comprises a wood veneer and/or a wood cover layer.

7. The covering element according to claim 1, wherein the stability layer is formed as a hard fiberboard and/or as a wood layer; and/or wherein the stability layer is designed as a shaped fiberboard.

8. The covering element according to claim 1, wherein the damping layer comprises as material cork and/or a cork composite and/or a foam material and/or consists thereof; and/or wherein the damping layer has a modulus of elasticity chosen from at most 5 MPa, between 0.2 and 5 MPa, and between 2 and 4 MPa.

9. The covering element according to claim 1, wherein a countermove is provided and/or arranged on an underside of the carrier plate; and/or wherein the carrier plate is designed as a plate body chosen from an HDF and/or MDF board, and/or wherein the carrier plate is designed as a plate body comprising or consisting of plastic.

10. The covering element according to claim 9, wherein the at least two layers of the covering element and/or the damping layer, the carrier plate, the stability layer, the countermove and/or the upper layer structure have been pressed together to form a laminate, at least one layer being treated with melamine resin; and/or wherein at least two layers, preferably all layers, of the covering element have been adhered to one another with the carrier plate, the stability layer and the damping layer being adhered to one another.

11. Method A method for producing a covering element according to claim 1, the method comprising the following method steps: A) Providing a carrier plate and a stability layer; B) Bonding the carrier plate to a damping layer by extruding the damping layer at least indirectly onto the carrier plate and/or by pressing and/or laminating the carrier plate and the damping layer together; C) Bonding the damping layer to the stability layer by means of pressing and/or laminating; D) Bonding the stability layer to an upper layer structure by means of pressing and/or laminating.

12. The method according to claim 11, wherein the method steps B) and C) and/or C) and D) are carried out simultaneously.

13. The method according to claim 11, wherein the upper layer structure has been provided before bonding with the stability layer or is produced when bonding with the stability layer.

14. The method according to claim 11, wherein first the carrier plate, the damping layer and the stability layer are adhered to each other and subsequently pressed with the upper layer structure; or wherein first the upper layer structure is pressed with the stability layer and then the damping layer is adhered with the stability layer and the carrier plate.

15. The method according to claim 11, wherein at least one preproduct is provided, the preproduct, being obtained by bonding the damping layer, the stability layer and the upper layer structure or by bonding the carrier plate to the damping layer or by bonding the stability layer to the upper layer structure or by bonding the carrier plate, the damping layer and the stability layer.

16. The covering element according to claim 3, wherein the carrier plate has connecting geometries of complementary design on opposite edge sides.

17. The covering element according to claim 5, wherein the decorative layer comprises a decorative film and/or a decorative paper and/or a decorative print and/or a decorative lacquer layer; and wherein the upper wear layer comprises an overlay and/or a protective lacquer and/or protective oil and/or protective film.

18. The covering element according to claim 17, wherein the upper wear layer is formed as an overlay comprising polyurethane (PUR) and/or consisting thereof.

19. The covering element according to claim 7, wherein the stability layer is formed as a MDF and/or HDF board and/or as a HFM/MB and/or as a HFH/HB board; and/or wherein the stability layer is designed as a shaped natural fiberboard comprising and/or consisting of recycled materials chosen from cellulose fibers and/or agricultural waste.

20. The covering element according to claim 8, wherein the damping layer comprises cork and polypropylene (PP), polyethylene (PE) and/or polyurethane (PUR) and/or other elastic plastics.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0072] It shows:

[0073] FIG. 1 is a schematic layer structure of a covering element according to the invention,

[0074] FIG. 2 is a schematic layer structure of a further embodiment of a covering element according to the invention,

[0075] FIG. 3 is a schematic layer structure of a further embodiment of a covering element according to the invention,

[0076] FIG. 4 is a schematic perspective view of a covering element according to the invention,

[0077] FIG. 5 is a schematic perspective view of a covering according to the invention,

[0078] FIG. 6 is a schematic representation of a method according to the invention,

[0079] FIG. 7 is a schematic representation of a method step according to the invention for forming a preproduct according to the invention,

[0080] FIG. 8 is a schematic representation of a further embodiment of a method according to the invention,

[0081] FIG. 9 is a schematic representation of a further embodiment of a method according to the invention, and

[0082] FIG. 10 is a schematic representation of a further embodiment of a method according to the invention.

DETAILED DESCRIPTION

[0083] FIG. 1 shows a layer structure of a covering element 1. The covering element 1 is intended for use to form a floor, wall and/or ceiling covering 2. To form a covering 2, several covering elements 1 can be connected to each other. A covering 2 is shown schematically in FIG. 5. In particular, a laminate covering element is provided as the covering element 1.

[0084] FIG. 1 shows that the covering element 1 has an upper layer structure 3. The upper layer structure 3 can be single-layer or multilayer. A stability layer 4 adjoins the upper layer structure 3 on the rear side. The stability layer 4 is made of wood and/or a wood-based material. As FIG. 1 shows, a damping layer 5 adjoins the stability layer 4 on the rear side. The damping layer 5 is an elastic and/or acoustically damping layer. In turn, a carrier plate 6 adjoins the damping layer 5 on the rear side. The carrier plate 6 can be designed as a plate body. In the embodiment example shown in FIG. 1, a countermove 15 is also provided, which can optionally be provided on the rear side of the carrier plate 6.

[0085] A multilayer design of the upper layer structure 3 is shown in FIG. 2, among others.

[0086] The stability layer 4 consists to a large extent of wood, wood particles and/or wood fibers. In particular, the material proportion of wood, which can be provided as coherent wood, wood particles and/or wood fibers, in the stability layer 4 is at least 65% by weight, preferably at least 70% by weight, in particular at least 80% by weight.

[0087] The damping layer 5 ensures the damping properties for the covering element 1. The damping layer 5 can ultimately provide a high level of comfort on the upper side of the covering element 1, which ultimately represents the useable side. Via the stability layer 4, on the other hand, load balancing/load distribution can be ensured when the covering element 1 is subjected to loads, in particular when mechanical stresses act on the covering element 1, such as walking on a floor covering 2. The load distribution can ultimately ensure a long service life for the covering element 1, while at the same time also making advantageous use of the damping properties of the damping layer 5. The stability layer 4 also protects the damping layer 5 from further external influences, so that the functionality of the damping layer 5 can be guaranteed over a long period of use.

[0088] Furthermore, the integration of the damping layer 5 in the layer structure of the covering element 1 has the advantage that a separate provision of a damping layer 5 underneath a covering 2 can be omitted, which can significantly reduce the installation effort for a damping floor covering 2. In particular, the covering element 1 shown in the embodiments can be laid in a manner known to the user without requiring any further special modification during laying. This also reduces laying errors.

[0089] The covering element 1 shown in FIG. 1 is PVC-free. However, the covering element 1 shown in FIG. 3 also contains PVC as a material.

[0090] Furthermore, the stability layer 4 shown in FIG. 1 is designed to be plastic-free or at least substantially plastic-free. A plastic-free design of the stability layer 4 does not exclude the possibility that it may have a resin content or an adhesive content, in particular for bonding the wood fiber components. Preferably, the plastic content of the material of the stability layer is less than 5% by weight, preferably less than 1% by weight, which is to be understood by a plastic-free formation of the stability layer 4.

[0091] In FIG. 4, it is shown that the carrier plate 6 and also the covering element 1 have connecting geometries 7 on their longitudinal sides. It is not shown in more detail that these connecting geometries 7 can also be provided on the head sides. In particular, tongue-and-groove connecting geometries of a click connection for connecting adjacent covering elements 1 are provided as connecting geometries 7. Preferably, the connecting geometries 7 are formed on opposite edge sides 8 of the carrier plate 6 and/or of the covering element 1 in a complementary manner. Thus, one long side can have a groove and the opposite long side can have a tongue formed complementary to the groove for forming the click connection. The connecting geometries 7 can ultimately be used to connect adjacent covering elements 1 to one another to form a covering 2, as shown schematically in FIG. 5.

[0092] FIG. 2 shows different thicknesses of the individual layers of the covering element 1. The stability layer 4 shown in FIG. 2 can have a thickness 9 between 0.3 to 5 mm, in particular between 0.5 to 2 mm. The damping layer 5, in turn, may have a thickness 10 between 0.3 to 5 mm, in particular between 0.5 to 2 mm. The thicknesses 9, 10 of the stability layer 4 and of the damping layer 5 can be at least substantially equal to one another or differ from one another.

[0093] Furthermore, the carrier plate 6 can have a thickness 11 between 2 to 15 mm, preferably between 4 to 10 mm. The thickness 11 of the carrier plate 6 is selected depending on the desired construction height and/or overall height of the covering element 1.

[0094] In FIG. 2, it is shown that the upper layer structure 3 has a decorative layer 12 and an upper wear layer 13. It is not shown in more detail that the upper layer structure 3 has only one decorative layer 12 or only one upper wear layer 13. The decorative layer 12 may be a decorative film, a decorative paper, a decorative print and/or a decorative lacquer layer. In turn, a protective film, an overlay and/or a protective lacquer and/or protective oil may be provided as the upper wear layer 13. The overlay in particular has corundum particles and/or is formed to contain corundum. This ultimately increases the resistance to wear.

[0095] It is not shown in more detail that the overlay has polyurethane (PUR) as a material and/or consists thereof. In particular, the upper wear layer 13 is designed as an overlay and as a protective film, the material of which is PUR and/or consists thereof. This design of the wear layer 13 ensures a sound-absorbing behavior of the wear layer 13.

[0096] The upper layer structure 3 may have a wood veneer and/or a wood cover layer 14. In FIG. 3, it is shown that the stability layer 4 is formed as a wood veneer and/or wood cover layer 14. Then, the stability layer 4 can also be considered as part of the upper layer structure 3. An upper layer structure 3 or an upper wear layer 13 for protecting the wood can then be applied to the wood veneer and/or wood cover layer 14, in particular a coating.

[0097] The stability layer 4 shown in FIG. 2 is designed as a hard fiberboard. In this context, various hard fiberboards are suitable, in particular a MDF and/or HDF board and/or a HFM/MB and/or a HFH/HB board. Alternatively, it can also be provided that the stability layer 4 is formed as a wood layer, in particular of poplar or lime. In this embodiment, it is particularly preferred if the stability layer 4 is formed as a wood veneer and/or wood cover layer 14, as previously explained, and in particular consists of poplar or lime.

[0098] It is not shown that the stability layer 4 is designed as a shaped fiberboard, in particular a shaped natural fiberboard. In particular, the shaped fiberboard may comprise waste cellulose as a material and/or consist thereof. Alternatively or additionally, the stability layer 4 formed as a shaped fiberboard may comprise and/or consist of recycled materials, in particular cellulose fibers and/or agricultural waste. In particular, the stability layer is designed as a flexible, high-density and compressed shaped fiberboard made of waste cellulose, which is preferably biodegradable.

[0099] The damping layer 5 shown in FIG. 1 has as material cork and/or a cork composite, in particular comprising cork and polypropylene (PP), polyethylene (PE) and/or polyurethane (PUR) and/or other elastic plastics. In further embodiments, it may be provided that the damping layer 5 comprises and/or consists of a foam material, in particular a plastic foam material. The foam material may also be cross-linked.

[0100] In addition, the damping layer can have a modulus of elasticity of at most 5 MPa and in particular between 2 to 4 MPa.

[0101] As previously explained, FIG. 1 shows that a countermove 15 is arranged on the underside of the carrier plate 6, which ultimately leads to the load distribution. In particular, a kraft paper can be provided as the countermove 15. In principle, the countermove 15 can be of single-layer or multi-layer design.

[0102] The carrier plate 6 shown in the embodiments is designed as a plate body and can be provided in particular as a hard fiberboard, preferably as a HDF and/or MDF board. In further embodiments not shown in more detail, the carrier plate 6 may also comprise or consist of a plastic material.

[0103] The layers of the covering element 1 can be bonded to each other in different ways, but this can also be seen in the final product as such.

[0104] Thus, at least two layers of the covering element 1 and/or the damping layer 5, the carrier plate 6, the stability layer 4 and/or the upper layer structure 3 may have been pressed together. In the case of pressing, it is particularly preferred if at least one layer is resinated, in particular at least one layer of the upper layer structure 3 or of the countermove 15.

[0105] FIG. 10 shows, for example, that the upper layer structure 3 has been pressed together with the stability layer 4 and the carrier plate 6 has been pressed together with the countermove 15, wherein in this connection the countermove 15 and the decorative layer 12 have been resinated and/or through-impregnated.

[0106] During pressing, a resin bonding layer can alternatively also be arranged between the layers to be pressed, which penetrates into the adjacent layers during pressing and bonds them firmly/materially to one another. Melamine resin is preferably provided as the resin.

[0107] Alternatively or additionally, it can also be provided that preferably two layers, in particular all layers, of the covering element 1 have been adhered together. In particular, the carrier plate 6, the stability layer 4 and the damping layer 5 can be adhered together, as shown for example in FIG. 9. Also, an adhering of the layers may be combined to a pressing of other layers, as it will be described in connection with the method.

[0108] FIG. 6 shows a schematic process flow of a method for producing a covering element 1 according to one of the embodiments described above. The method comprises steps A) to D). In step A), the carrier plate 6 and the stability layer 4 are first provided.

[0109] In method step B), the carrier plate 6 is then bonded to a damping layer 5. Bonding can take place, for example, by extrusion of the damping layer 5 onto the carrier plate 6, in particular if the material of the damping layer 5 is foam or consists thereof. Alternatively, it can be provided that the carrier plate 6 and the damping layer 5 are pressed and/or laminated to each other, wherein a connection to further layers of the covering element 1 can also be carried out during this connection method.

[0110] In the process flow shown in FIG. 6, method step C) is carried out at the same time as and/or simultaneously with method step B). However, a temporally independent execution can also be provided in further embodiments, which are not shown in more detail. In step C), the damping layer 5 is bonded to the stability layer 4, preferably by means of pressing and/or laminating. For example, the damping layer 5, the stability layer 4 and the carrier plate 6 can be bonded, in particular adhered, to each other at the same time.

[0111] In method step D), which in the embodiment example shown in FIG. 6 is carried out chronologically after method steps B) and C), the stability layer 4 can be bonded to the upper layer structure 3, preferably by means of pressing and/or laminating.

[0112] As explained above, method steps B) and C) can be carried out simultaneously. It is not shown in more detail that method steps C) and D) are also carried out alternatively or additionally at the same time. Also not shown in more detail is that the layers of the covering element 1 are pressed together and/or adhered together at least substantially simultaneously. In the embodiments of the method shown in FIGS. 8 to 10, it is provided that different preproducts 16 are provided for forming the covering element 1, which can be produced by bonding individual layers of the covering element 1, wherein these preproducts 16 can be bonded to further preproducts 16 or layers of the covering element 1.

[0113] The upper layer structure 3 may have been provided before bonding to the stability layer 4 or may be produced when bonded to the stability layer 4. If the upper layer structure 3 is formed in several parts, the upper layer structure 3 can be produced as such, in particular during the connection to the stability layer 4.

[0114] A preproduct 16 can be provided by bonding different layers of the covering element 1. Such a preproduct 16 can be intermediately stored, in particular, prior to bonding to other layers of the covering element 1. In FIG. 7, it is shown that a preproduct 16 can be produced by bonding, in particular adhering, the stability layer 4, the damping layer 5 and the carrier plate 6.

[0115] FIG. 10 again shows two preproducts 16. One preproduct 16 may have been produced by bonding the upper layer structure 3 to the stability layer 4 and another preproduct 16 may have been produced by bonding the carrier plate 6 to the carrier plate 15, in particular by pressing.

[0116] Not shown in more detail is that a preproduct 16 can also be provided by bonding the damping layer 5, the stability layer 4, and the upper layer structure 3, or by bonding the carrier plate 6 to the damping layer 5.

[0117] In particular, the provision of a preproduct 16 may be a function of the particular storage capacity or manufacturing method.

[0118] In addition, the connecting geometries 7 can be introduced at the edge sides into the carrier plate 6 and/or into the covering element 1 after the covering element 1 has been bonded. Alternatively, it is also possible for the edge sides of the carrier plate 6 to have the connecting geometries 7 before it is bonded to other layers.

[0119] FIGS. 8 to 10 show different schematic representations of a respective method.

[0120] FIG. 8 shows that a preproduct 16 can first be produced by bonding the stability layer 4, the damping layer 5 and the carrier plate 6. In particular, these layers can be bonded together by adhering. Subsequently, the preproduct 16 is pressed with the upper layer structure 3 and optionally with the countermove 15, in particular in a short-cycle pressing plant. In this context, it is particularly preferred if the countermove 15 and/or at least one layer, preferably the decorative layer 12, of the upper layer structure 3 is at least partially, preferably completely, resinated and/or impregnated through, especially preferably resinated, impregnated and/or soaked with melamine resin.

[0121] In particular, a melamine resin is provided as the resin.

[0122] If the layers are not treated with resin, a bonding layer (not shown in detail) is preferably arranged between the layers to be pressed. The bonding layer can then contain resin, in particular melamine resin, as the material and penetrate the adjacent layers during pressing.

[0123] FIG. 8 shows that the upper layer structure 3 is formed during pressing and is composed of the upper wear layer 13 and the decorative layer 12.

[0124] FIG. 9 shows that the preproduct 16 is first formed by bonding, in particular adhering, the stability layer 4, the damping layer 5 and the carrier plate 6. Subsequently, the upper layer structure 3, which can be formed in one or more layers, and optionally the countermove 15 are laminated to this preproduct 16. In the case of lamination, a laminating agent is provided that ultimately ensures a material bond. In this embodiment, the carrier plate 6 can have plastic as the material, but does not have to.

[0125] In FIG. 10, a further alternative method embodiment is again provided, in which two preproducts 16 are initially formed, wherein one preproduct 16 can be formed by pressing the upper layer structure 3 to form the stability layer 4, wherein the upper layer structure 3 can be formed in particular by a decorative layer 12 and an upper wear layer 13. The further preproduct 16 can be formed by bonding, in particular pressing, the carrier plate 6 to the countermove 15.

[0126] As previously discussed, it is particularly advantageous in a pressing process if at least one layer is treated and/or impregnated or if a resin bonding layer is provided between the layers to be pressed. Subsequently, the preproducts 16 are bonded, preferably adhered and/or laminated, to form the damping layer 5.

[0127] It is not shown in more detail that the damping layer 5 can also be formed already during extrusion onto the carrier plate 6 and subsequently adhered, laminated and/or pressed to form further layers.

LIST OF REFERENCE SIGNS

[0128] 1 Covering element [0129] 2 Covering [0130] 3 Upper layer structure [0131] 4 Stability layer [0132] 5 Damping layer [0133] 6 Carrier plate [0134] 7 Connecting geometries [0135] 8 Edge side of 1 [0136] 9 Thickness from 4 [0137] 10 Thickness from 5 [0138] 11 Thickness from 6 [0139] 12 Decorative layer [0140] 13 Upper wear layer [0141] 14 Wood cover layer/wood veneer layer [0142] 15 Countermove [0143] 16 Preproduct