Method and Installation for Manufacturing a Floor Covering Product and Floor Covering Product Obtained Hereby

Abstract

A method for manufacturing a floor covering product comprises at least a first step of forming a single- or multi-layered substrate by consolidating synthetic material-based starting material. The method comprises a second step after the first step, which is performed in line with the first step. The at least one continuous film is laminated onto the substrate, and the laminating is performed by means of a belt press.

Claims

1-43. (canceled).

44. A method for manufacturing a floor covering product, the method comprising: a first step of forming a single- or multi-layered substrate by consolidating synthetic material-based starting material; and after the first step a second step performed in line with the first step, wherein at least one continuous film is laminated onto the substrate, wherein said laminating is performed by means of a belt press.

45. The method of claim 44, wherein the forming of the substrate is performed by means of a strewing process, wherein the synthetic material-based starting material is strewn as a granulate and subsequently is consolidated in a press device.

46. The method of claim 45, wherein the strewn granulate is consolidated by means of a continuous press, more particularly a belt press, and in particular a double belt press.

47. The method of claim 44, wherein the forming of the substrate is performed by means of extrusion wherein the synthetic material-based material is extruded in layer shape, or by means of a comparable process, wherein a plurality of layers are thermally laminated on top of each other.

48. The method of claim 44, wherein the step of forming the substrate shows one or more of the following characteristics: that in the starting material, one or more other materials than synthetic materials are incorporated, such as additives and/or fillers, amongst others, chalk; that reinforcement material, more particularly fibers, are included in the substrate in the form of one or more local layers in the form of a fiber mat, non-woven or fabric on the basis of glass fiber.

49. The method of claim 44, wherein said laminating of the continuous film in said second step is performed by means of a double belt press.

50. The method of claim 44, wherein said laminating of the continuous film in said second step is performed by means of a belt press which is made as an isobaric press.

51. The method of claim 44, wherein said laminating of the continuous film in the belt press in said second step is performed by means of a fluid pressure which is exerted on a surface of a belt of the belt press in a zone along which this belt is moving.

52. The method of claim 44, wherein in said second step a double belt press is applied, wherein the substrate and the continuous film are moved along between the two belts of the double belt press, wherein the fluid pressure is exerted on the belt which is located on the side of the continuous film, wherein the other belt acts as a counter support.

53. The method of claim 50, wherein during laminating, in said second step, instead of said belt press use is made of another press, which press is an isobaric press for pressing the film directly or indirectly with a uniform fluid pressure over a surface of the substrate onto this latter.

54. The method of claim 50, wherein for creating the pressure in the press, use is made of a gaseous fluid, or according to an alternative, of a liquid.

55. The method of claim 44, wherein laminating the film on the substrate is performed by fusing, and wherein for the purpose of providing a fusion, the substrate and/or the film to be provided thereon by lamination are brought to a suitable temperature.

56. The method of claim 44, wherein towards the end of laminating, a cooling is provided for consolidating the assembly of substrate and film, and wherein use is made of a fluid pressure which is exerted directly or indirectly on a surface of a belt of the belt press, wherein the cooling is performed via this fluid.

57. The method of claim 44, wherein said continuous film is a decor film provided with a print and wherein the decor layer is printed directly, thus, during the manufacturing process, however, prior to laminating, by means of a digital printer or digital printing unit.

58. The method of claim 44, wherein impressions are provided in the upper side of the floor covering product in one and the same continuous process after laminating the continuous film onto the substrate, and wherein the impressions are realized as so-called in register with the decor.

59. The method of claim 58, wherein the impressions are applied by means of a roller provided with a relief on its surface.

60. The method of claim 44, wherein said continuous film is a decor layer and wherein 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.

61. The method of claim 44, wherein the substrate and said continuous film, whether or not together with still other layers, form a material web and wherein this material web is cut to floor panels to rectangular oblong or square panels or tiles.

62. The method of claim 61, wherein it is applied for the production of so-called LVT tiles or comparable floor panels.

63. The method of claim 44, wherein instead of using said continuous film, use is made of successive film sheets which are laminated on the continuously formed substrate.

64. The method of claim 44, wherein the substrate shows one or more of the following characteristics: the material of the substrate contains a thermoplastic; the material of the substrate contains a supple thermoplastic provided with a plasticizer; the material of the substrate is based on any of the following materials: polyvinyl chloride (PVC), polypropylene (PP), polyethylene (PET) or polyurethane (PUR); the material of the substrate contains one or more filler materials including chalk; the material of the substrate, either across the entire thickness thereof, or across only a portion of the thickness thereof, substantially consists of a composite of synthetic material and wood particles, and more particularly WPC (Wood Plastic Composite), wherein for the synthetic material use is made of any of the herein above-mentioned synthetic materials; the substrate consists of at least two layers, namely, a layer such as described in the preceding paragraph, and a layer which is free or substantially free from wood particles and substantially is based on synthetic material; the substrate contains a reinforcement layer, such as a glass fiber fleece or the like.

65. The method of claim 44, wherein the continuous film shows one or more of the following characteristics: it relates to a thermoplastic synthetic material film; it relates to a PVC film, PU film, PP film, or PET film; it relates to an oriented polypropylene film; it relates to a hard PVC film, namely, a film on the basis of PVC without plasticizer or with an amount of plasticizer of less than 5 percent by weight.

66. The method of claim 44, wherein the substrate, starting from its manufacture up to the forming of the final floor covering product, is handled in a flat state, or, during bending, is subjected exclusively to bending having a radius of more than 40 cm.

67. A method for manufacturing a floor covering product, the method comprising: at least a first step for forming a single- or multi-layered substrate by consolidating synthetic material-based starting material; a second step after the first step performed in line with the first step, wherein at least one continuous film is laminated on the substrate; a third step, wherein impressions are formed in the surface, with the characteristic: that the forming of the substrate is performed by means of a strewing process, wherein the synthetic material-based starting material is strewn as a granulate and subsequently is consolidated in a press device; and that the impressions are provided by means of a roller, which is provided with a relief on its surface, wherein for this roller a 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 so-called repeat with which the impressions are realized, wherein this repeat is adjusted and altered in function of the position of an applied decor.

Description

[0092] 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:

[0093] FIG. 1 schematically illustrates a possible embodiment of the method of the invention, as well as schematically represents the installation applied therewith;

[0094] FIG. 2 represents a variant.

[0095] 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.

[0096] 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.

[0097] 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.

[0098] 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. In this manner, a uniform pressure is realized during laminating, by which a smooth lamination is created.

[0099] 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.

[0100] 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

[0101] 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.

[0102] 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.

[0103] 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.

[0104] 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.

[0105] 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.

[0106] 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.

[0107] 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.

[0108] 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.

[0109] 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.

[0110] 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.

[0111] 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.

[0112] 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.

[0113] 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:

[0114] WO 2013/179261

[0115] BE 2014/0517

[0116] PCT/IB2014/058464

[0117] 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.

[0118] 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.

[0119] 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.

[0120] 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.

[0121] 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.

[0122] 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.

[0123] 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.