METHOD FOR PRODUCING A VISIBLE COVERING

Abstract

The invention relates to a method for producing a visible covering (1) comprising the following steps: mixing a stabilising agent with a granular material (2), introducing the granular material (2) into a receiver (3) to form a moulded article (4), connecting of at least a surface layer (9) of the moulded article with a carrier layer (10), removing the composite of surface layer (9) and carrier layer (10), wherein the visible covering (1) is obtained. The invention further related to a visible covering (1) produced with the method according to the invention and the use thereof as a facing of ceilings, walls, floors, doors, roofs and/or tabletops.

Claims

1. A method for producing a visible covering comprising the following steps: a) mixing a weak stabilising agent selected from among water, swelling clay, methyl cellulose, polysaccharides, polyvinyl alcohol, casein, loam, saponite, sephiolite, china-clay, zinc oxide and/or water glass, or any combination thereof, with a granular material; wherein said granular material is selected from among natural stone, preferably quartz, quartz sand, sandstone, granite, slate, marble, tuff, glass, plastic, wood and/or metal, or any combination thereof; b) introducing the granular material into a receiver to form a moulded article; c) forming at least one recess in the moulded article; d) filling at least part of the recess with a contrast medium, wherein an artificial structure pattern forms; e) connecting at least a surface layer of the moulded article with a carrier layer, selected from a woven material, a non-woven material and/or a meshed material, or any combination thereof; f) removing the composite of surface layer and carrier layer, wherein the visible covering is obtained.

2. The method of claim 1 wherein said granular material is a granulate.

3. The method of claim 2, wherein said granular material is a granulate with a D50 value of about 0.02 mm to 1 mm and/or an average grain size of from about 0.1 mm-1.5 mm is used.

4. The method of claim 1, wherein said granular material comprises a fire-proofing additive, a hydrophobing agent, an odour absorber, a contaminant absorber, a reinforcing material and/or a colorant, or any combination thereof.

5. The method of claim 1, wherein the stabilising agent comprises water, cellulose, starch, saccharide, polyvinyl alcohol, casein, water glass, loam, saponite, sephiolite, china-clay, zinc oxide and/or swelling clay, or any combination thereof.

6. The method of claim 5, wherein the recess in the moulded article is formed by a change in the spatial position of the moulded article.

7. The method of claim 6, wherein the change in the spatial position of the moulded article is performed by selective, preferably one-sided, raising of the floor area of the receiver.

8. The method of claim 5, wherein the recess in the moulded article is formed by a deformation of the floor area of the receiver and/or by a deformation of a film arranged between the floor area of the receiver and the moulded article.

9. The method of claim 8, wherein the deformation of the floor area is performed by impressing an impression body.

10. The method of claim 5, wherein a contrast medium is used which in terms of grading curve structure, grain size, colour, structure and/or composition differs from the granular material.

11. The method of claim 1, wherein a receiver is used, wherein the floor area of said receiver is deformable.

12. The method of claim 11, wherein a receiver is used, wherein the floor area of said receiver is comprised of metal or an elastic plastic, preferably polyurethane, polyvinylchloride and/or silicon, or any combination thereof.

13. The method of claim 12, wherein a receiver is used, which comprises a reinforcing insert and/or filler.

14. The method of claim 13, wherein a receiver is used, on the walls and/or floor area of which a film, in particular of latex, polyisobutylene, polyethylene, silicon, polyurethane and/or urea, or any combination thereof, is arranged as a separating and/or sliding layer.

15. The method of claim 14, wherein a receiver is used, wherein the floor area of said receiver can be raised in the filling direction.

16. The method of claim 1, wherein a porous and/or flexible carrier layer is used.

17. The method of claim 1, wherein the connecting of the surface layer and carrier layer is performed with an adhesive and/or a binding agent.

18. The method of claim 1, wherein on the side of the carrier layer facing away from the surface layer a reinforcing layer is applied.

19. The method of claim 18, wherein a particle board and/or MDF board is used as the reinforcing layer.

20. The method of claim 1, wherein the surface of the moulded article before and/or after removing the composite of surface layer and carrier layer is smoothed.

21. The method of claim 1, wherein the visible covering is post-treated by pressing and/or polishing, by application of a sealing layer and/or by application of a protective layer, or any combination thereof.

22. The method of claim 1, wherein at least one place holder is introduced into the receiver and/or into the granular material.

23. A visible covering produced by the method of claim 1.

24. A use of the visible covering of claim 23 as a facing of ceilings, walls, floors, doors, roofs, furniture, and/or tabletops.

Description

[0109] In the following the invention is explained in more detail by reference to an embodiment shown in a drawing. This shows as follows:

[0110] FIG. 1: The introduction process of the granular material mixed with the stabilising agent into the receiver

[0111] FIG. 2: The formation of a recess in the moulded article by changing the spatial positioning of the moulded article

[0112] FIG. 3: The formation of a recess in the moulded article by impression of an impression body

[0113] FIG. 4: The filling of a recess with a contrast medium

[0114] FIG. 5: The removing of a composite of surface layer of the moulded article and a carrier layer to form the visible covering according to the invention

[0115] FIG. 6: A flow chart of a possible sequence of process steps for producing the visible covering according to the invention

[0116] FIG. 1 illustrates a process step for producing the visible covering 1 according to the invention. From a storage container (B) a granular material 2 is poured into a receiver 3, whereby a moulded article 4 forms. In the present case the granular material 2 is already mixed with a stabilising agent prior to filling. The mixing of granular material and stabilising agent can however also occur at a later instant, for example in the receiver 3. To this end the stabilising agent can be introduced into the receiver 3 separately from the granular material 2, for example from a further storage container (B). The granular material 2 and/or the stabilising agent can further comprise additives. These can either be introduced into the receiver 3 along with the granular material 2 and/or with the stabilising agent. The additives can, however, also be introduced separately for example via storage container (C).

[0117] FIG. 2 shows how by changing the spatial positioning of the moulded article 4 a recess 5 is formed. Here the bent arrows indicate a lateral raising of a flexible floor area 6 of the receiver 3.

[0118] FIG. 3 shows how a recess 5 is formed by impression of an impression body 7 into a flexible floor area 6 of the receiver 3.

[0119] FIG. 4 shows how a recess 5 is filled with a contrast medium 8.

[0120] FIG. 5 shows how by removing a composite of a surface layer 9 of the moulded article 4 and a carrier layer 10 a visible covering 1 according to the invention is obtained.

[0121] The flow chart in FIG. 6 illustrates a possible sequence of process steps for producing the visible covering 1 according to the invention.