METHOD FOR THE PRODUCTION OF A POLYVINYL CHLORIDE-FREE TOP LAYER, POLYVINYL CHLORIDE-FREE TOP LAYER AND DECKING ELEMENT

Abstract

The present invention relates to a method for producing a polyvinyl chloride-free top layer (1) for a decking element (3), the method comprising the method steps indicated below: A) Providing a base layer (4) comprising and/or consisting of plastic; B) Printing a décor (6) on a top (5) of the base layer (4) facing a usable side (7); C) Bonding, preferably laminating, a, preferably transparent, wearing surface (8) to the printed base layer (4) to form a, preferably solid, layer composite (9); D) Embossing the layer composite (9) at least in some areas, preferably over the entire surface, with a structure (10) at least substantially synchronous with the décor (6), the structure (10) being embossed in such a way that it is visible both on the top (11) facing the usable side (7) and at least in some areas on the bottom (12) of the layer composite (9) facing away from the usable side (7); E) Application of a surface sealing layer (17), preferably a lacquer layer, to the top (11) of the layer composite (9) facing the usable side (7); F) optionally: curing of the surface sealing layer (17), preferably the lacquer layer.

Claims

1. A method of producing a polyvinyl chloride-free top layer for a decking element, the method comprising the method steps indicated below: A) Providing a base layer comprising and/or consisting of plastic; B) Printing a décor on a top of the base layer facing a usable side; C) Bonding, preferably laminating, a, preferably transparent, wearing surface to the printed base layer to form a, preferably solid, layer composite; D) Embossing the layer composite at least in some areas, preferably over the entire surface, with a structure at least substantially synchronous with the décor, the structure being embossed in such a way that it is visible both on the top facing the usable side and at least in some areas on the bottom of the layer composite facing away from the usable side; E) Application of a surface sealing layer, preferably a lacquer layer, to the top of the layer composite facing the usable side; F) optionally: curing of the surface sealing layer, preferably the lacquer layer.

2. The method according to claim 1, wherein the application of the surface sealing layer, preferably the lacquer layer, takes place before or after the embossing of the layer composite and/or in that the curing of the surface sealing layer, preferably the lacquer layer, takes place before or after the embossing of the layer composite and/or in that the curing of the surface sealing layer, preferably the lacquer layer, is carried out by means of electron beam curing.

3. The method according to claim 1, wherein a first adhesion promoter layer is applied to the bottom of the base layer and/or in that another adhesion promoter layer is applied at least in regions after formation of the layer composite and before application of the surface sealing layer, preferably the lacquer layer, is applied to the top of the wearing surface facing away from the base layer, in particular wherein the surface sealing layer, preferably the lacquer layer, is applied to the other adhesion promoter layer.

4. The method according to claim 1, wherein the wearing surface is bonded to the base layer by means of lamination by pressure and/or heat, and/or in that, during lamination, a laminating agent is used to bond the wearing surface to the base layer, in particular varnish, glue and/or resin being used as the laminating agent and/or, in particular, the laminating agent being applied, at least in regions, to the bottom of the wearing surface facing away from the usable side and/or to the top of the base layer before lamination, and/or in that the wearing surface is joined to the base layer to form the layer composite by means of lamination.

5. The method according to claim 1, wherein the embossing of the layer composite is carried out by means of a structural cylinder, in particular wherein the layer composite is embossed and/or heated for embossing, and/or in that the décor is printed onto the base layer by means of offset printing, flexographic printing, rotogravure printing, digital printing, gravure printing and/or screen printing.

6. The polyvinyl chloride-free top layer provided for connection, preferably for lamination, to a carrier plate of a decking element, in particular wherein the top layer has been produced by a method according to claim 1, wherein the top layer has a base layer printed with a décor and a wearing surface, wherein the base layer and the wearing surface are firmly connected to one another to form a layer composite, wherein the layer composite s embossed at least in regions with a structure at least substantially synchronous with the décor, wherein the structure is apparent both on the top and at least in regions on the bottom of the layer composite, wherein a hardened surface sealing layer, preferably a lacquer layer, is provided on the top of the layer composite.

7. The top layer according to claim 6, wherein the structure, preferably on the top of the layer composite and/or the top layer, has a maximum depth of up to 1 mm, preferably up to 0.5 mm, more preferably between 0.05 mm to 0.2 mm, and/or in that the structure on the bottom of the layer composite and/or of the top layer of at most 100 μm, preferably at most 90 μm, further preferably between 30 μm to 90 μm, and/or that the top layer of at least 0.1 mm, preferably between 0.1 and 0.4 mm, more preferably between 0.2 and 0.3 mm.

8. The top layer according to claim 6, wherein the base layer is formed as a base film and/or base foil and/or in that the base layer and/or the wearing surface has as polyvinyl chloride-free material a thermoplastic and/or consists thereof, in particular polypropylene, polyethylene and/or polyurethane.

9. The decking element, in particular intended for use as a floor, wall and/or ceiling covering element for a floor, wall and/or ceiling covering, having at least one carrier plate and at least one top layer according to claim 6, the bottom of the top layer facing away from a usable side being firmly connected to the top of the carrier plate facing the usable side.

10. The decking element according to claim 9, wherein the corresponding tongue and groove connection geometries, in particular for forming a click connection, with a groove side having a groove and a tongue side having a tongue and located opposite the groove side are provided on opposite sides of the carrier plate and/or in that corresponding snap fastener and/or bayonet connection geometries are provided on opposite sides of the carrier plate and/or in that a countermove, in particular a countermove comprising kraft paper and/or a cork layer and/or an expanded polyolefin (XPO), is arranged facing the bottom of the carrier plate, and/or in that the carrier plate is designed as a HDF plate (high-density fiberboard), a real wood layer and/or a MDF plate (medium-density fiberboard) and/or in that the carrier plate has a plastic as material and/or consists thereof, preferably polypropylene and/or polyethylene and/or in that the carrier plate is designed to be free of polyvinyl chloride and/or that the carrier plate has a layer thickness of at least 2 mm, preferably between 3 to 10 mm, more preferably between 4 to 7 mm.

Description

[0086] Further features, advantages and possible applications of the present invention will be apparent from the following description of examples of embodiments based on the drawing and the drawing itself. In this context, all the features described and/or illustrated constitute the subject-matter of the present invention, either individually or in any combination, irrespective of their summary in the claims or their relation back.

[0087] It shows:

[0088] FIG. 1 a schematic representation of a method sequence according to the invention for the production of a polyvinyl chloride-free top layer according to a first embodiment,

[0089] FIG. 2 a schematic representation of a method sequence according to the invention for the production of a polyvinyl chloride-free top layer according to a second embodiment,

[0090] FIG. 3 a schematic representation of a method sequence according to the invention for the production of a polyvinyl chloride-free top layer according to a third embodiment,

[0091] FIG. 4 a schematic representation of a method sequence according to the invention for the production of a polyvinyl chloride-free top layer according to a fourth embodiment,

[0092] FIG. 5 a schematic representation of a method sequence according to the invention for the production of a polyvinyl chloride-free top layer according to a fifth embodiment,

[0093] FIG. 6 a schematic cross-sectional view of a top layer according to the invention,

[0094] FIG. 7 a schematic cross-sectional view of a further embodiment of a top layer according to the invention,

[0095] FIG. 8 a schematic cross-sectional view of a further embodiment of a top layer according to the invention,

[0096] FIG. 9 a schematic cross-sectional view of a further embodiment of a top layer according to the invention,

[0097] FIG. 10 a schematic cross-sectional view of a further embodiment of a top layer according to the invention,

[0098] FIG. 11 a schematic cross-sectional view of a further embodiment of a top layer according to the invention,

[0099] FIG. 12 a schematic cross-sectional view of a further embodiment of a top layer according to the invention,

[0100] FIG. 13 a schematic cross-sectional view of a decking element according to the invention,

[0101] FIG. 14 a schematic cross-sectional view of a decking element according to the invention in accordance with a further embodiment, and

[0102] FIG. 15 a schematic perspective view of a decking element according to the invention in accordance with a further embodiment.

[0103] FIG. 1 shows a flow chart of a method for producing a polyvinyl chloride-free top layer 1. The top layer 1 can have a multilayer structure, as shown schematically in FIG. 6. The top layer 1 can be provided for lamination or for bonding to a carrier plate 2 of a decking element 3.

[0104] In FIG. 1, the individual method steps have been identified by letters. In this context, each letter refers to an individual method step, as will be explained below.

[0105] The method step denoted by A in FIG. 1 involves the provision of a base layer 4 comprising and/or consisting of plastic. A base layer 4 is shown schematically in FIG. 6, for example.

[0106] Following method step A, step B provides for the top 5 of the base layer 4 to be printed with a décor 6. By printing with the décor 6, a décor 6 can ultimately be provided. The top 5 of the base layer 4 faces a usable side 7. The usable side 7 ultimately represents the side of use in the installed state of the decking element 3—for example, the running surface when the decking element 3 is used as a floor covering element.

[0107] In FIG. 1, following method step B, method step C provides for the base layer 4 to be bonded to a wearing surface 8. The wearing surface 8 is in particular transparent or at least substantially transparent. Preferably, in method step B, a laminating method is provided for joining the base layer 4 and the wearing surface 8. After bonding the layers 4, 8, a layer composite 9 is obtained, which may have layers 4, 8 firmly bonded to one another. In addition to the wearing surface 8 and/or the base layer 4, the layer composite 9 may also comprise further layers.

[0108] It should be noted at this point that further method steps can also be provided between the individual method steps shown. Finally, the schematic sequence of the individual method steps shown is visualized in the flow charts shown in FIGS. 1 to 5.

[0109] Furthermore, the successive method steps can be carried out at least substantially immediately one after the other or with a time delay.

[0110] For example, a further method step, such as intermediate storage of the base layer, can be provided between method step A and step B. The time intervals between the individual method steps following one another also can also differ.

[0111] FIG. 1 further shows that subsequently to method step C in method step D it is provided that the layer composite 9 is embossed at least in some areas, preferably over the entire surface, with a structure 10 that is at least substantially synchronous with the décor 6. The structure 10 is embossed in such a way that it is visible both on the top 11 of the layer composite 9 facing the usable side 7 and on at least some areas of the bottom 12 of the layer composite 9 facing the usable side 7. The structure 10 can be formed on the top 11 by recesses 13. Protrusions 14 on the bottom 12 of the layer composite 9 may correspond to the recesses 13 on the top 11. In this context, the depth 15 of a first recess 13 can differ from the height 16 of the first protrusion 14 corresponding to the first recess 13, so that the height 16 can be formed smaller than the depth 15, as this is shown schematically in FIG. 12, for example.

[0112] After method step D, in method step E, as can be seen schematically from FIG. 1, a surface sealing layer 17, preferably a lacquer layer, can be applied to the top 11 of the layer composite 9 facing the usable side 7.

[0113] Following method step E, method step F provides for the surface sealing layer 17, preferably the lacquer layer, to be cured.

[0114] FIG. 15 shows schematically that embossing of the structure 10 synchronously with the décor means that the embossed structure 10 is ultimately oriented at least substantially to the décor 6 and, in particular, is formed at least substantially synchronously with the décor 6—i.e., for example, that at least some elements 18 of the décor 6 correspond to the structure 10 in such a way that a recess shown as element 18 corresponds at least substantially to an actual recess 13 on the top 11 of the layer composite 9. Minor deviations due to the manufacturing method may occur and amount to a maximum of 2 mm+/−1 mm, for example.

[0115] In particular, shown cracks, knots or the like of the décor 6 can correspond to corresponding recesses 13. In this context, it is understood that further elements 18 of the dé-cor 6 may also be present which do not correspond to the structure 10. Ultimately, a dé-cor-synchronous embossing is to be understood as meaning that several elements 18 of the décor 6 or also individual partial areas are formed synchronously with the structure 10—even if further elements 18 or further partial areas of the décor 6 have an asynchronous structure 10.

[0116] The protrusion 14 on the bottom 12 is designed in such a way that good adhesion or adhesiveness can still be ensured during subsequent application and/or subsequent bonding, in particular lamination, of the top layer 1 to the carrier plate 2. Thus, the structure 10 can thus become visible on the bottom 12, but the adhesion of the entire top layer 1 continues to be ensured.

[0117] FIG. 2 shows that the application of the surface sealing layer 17 in method step E can also take place before the embossing step D. The curing in method step F of the surface sealing layer 17 can thereby take place before or after the embossing in step D. FIG. 2 shows that curing F takes place after embossing D. method steps A to C are preferably still carried out in succession, as the comparison of FIG. 1 with FIG. 2 makes clear.

[0118] FIG. 3 shows that the surface sealing layer 17 in method step F is applied before the embossing in method step D. Thus, the hardening in method step F can take place after the application of the surface sealing layer 17 in method step E—but before or after the embossing in method step D.

[0119] FIG. 4 shows that a further method step and/or method step G is provided, which in the embodiment shown is carried out before method step C (namely the bonding of the wearing surface 8 and the base layer 4 to form a layer composite 9). In method step G, a first adhesion promoter layer 19 is applied to the bottom of the base layer 4—that is, to the bottom 20 of the base layer 4. The first adhesion promoter layer 19 is shown schematically in FIG. 9. The method step G can also take place and/or be carried out after the method steps C, D, E and/or F, in particular after the method step F has been carried out.

[0120] In principle, it can also be envisaged that method step G can be carried out at least substantially simultaneously with method step B.

[0121] FIG. 5 shows the integration of method step H into the schematic method sequence. method step H can be carried out in addition to or as an alternative to method step G. In method step H, it is provided that another adhesion promoter layer 21, as shown schematically in FIG. 9, is applied at least in certain areas after formation of the layer composite 9 (cf. method step C) and before application of the surface sealing layer 17 (cf. method step E) on the top 11 of the wearing surface 8 facing away from the base layer 4. Accordingly, the other adhesion promoter layer 21 can be arranged between the wearing surface 8 and the surface sealing layer 17, whereby the surface sealing layer 17 can be applied to the further adhesion promoter layer 21.

[0122] Ultimately, the other adhesion promoter layer 21 serves to improve the bonding and/or connection of the surface sealing layer 17 with the wearing surface 8.

[0123] Both the first adhesion promoter layer 19 and/or the other adhesion promoter layer 21 may comprise or consist of a primer.

[0124] In addition, method step H can be carried out before or after embossing in step D. FIG. 5 shows that method step H is carried out after embossing of the layer composite 9 with the structure 10.

[0125] Not shown is that in step C, a lamination method is used to bond the base layer 4 to the wearing surface 8, wherein the wearing surface 8 is bonded to the base layer 4 by pressure and/or heat. Such a method may also be referred to as thermal lamination.

[0126] FIG. 8 schematically shows that a laminating agent 22 is used for lamination in step C.

[0127] The laminating agent 22 can ultimately also form a layer which is arranged at least in certain areas, preferably over the entire surface, on the top 5 of the base layer 4 and/or on the top 23 of the décor 6. The laminating agent 22 may be an adhesive, in particular a varnish, glue and/or resin.

[0128] Before lamination (in method step C), the laminating agent 22 can be applied to the bottom 24 of the wearing surface 8 facing away from the usable side 7 and/or to the top 5 of the base layer 4 and/or to the top 23 of the décor 6, at least in certain areas. In this context, it is understood that the top 5 of the base layer 4 can also be understood to mean the top 23 of the décor 6. Preferably, an at least substantially full-surface application of the laminating agent 22 is provided.

[0129] In an alternative embodiment, not shown, it can be provided that the wearing surface 8 is joined to the base layer 4 to form the layer composite 9 in method step C by means of lamination. During lamination, it is possible in particular to dispense with the use of a laminating agent 22 or a further auxiliary material for bonding.

[0130] Furthermore, it is not shown that in method step D the embossing of the structure 10 is carried out by means of a structure cylinder, wherein the cylinder can roll on the surface of the top layer 1 and thereby presses and/or embosses the structure 10 into the top layer 1 or the layer composite 9.

[0131] Not shown is that the décor 6 can be applied to the base layer 4 by means of a printing cylinder and/or by means of print heads in a digital printing process.

[0132] Accordingly, the layer composite 9 can be embossed and/or heated during embossing, preferably by means of pressure and/or heat.

[0133] Further, it is not shown that the décor 6 is printed on the base layer 4 using offset printing, flexographic printing, digital printing, gravure printing, and/or screen printing.

[0134] Alternatively or additionally, it can also be provided that the printing of the décor 6 is built up from several individual image layers, in particular wherein the printing is carried out by a rotogravure printing process. This embodiment is also not shown in more detail.

[0135] FIG. 6 shows a polyvinyl chloride-free top layer 1. The top layer 1 is provided for bonding, preferably for lamination, to a carrier plate 2 of a decking element 2, as can be seen schematically from FIGS. 13 to 15. The top layer 1 may have been produced by a method according to any of the preceding embodiments.

[0136] The top layer 1 shown in FIG. 7 has a base layer 4 printed with a décor 6 and a wearing surface 8. The base layer 4 and the wearing surface 8 are firmly bonded to one another—at least in some areas—to form a layer composite 9. The layer composite 9 can be embossed, at least in some areas, with a structure 10 that is at least substantially synchronous with the décor 6.

[0137] What is meant by a décor-synchronous structure 10 has already been explained.

[0138] Ultimately, at least substantially and at least in some areas, some elements 18 of the décor 6 coincide with corresponding recesses 13 of the layer composite 9. Preferably, a full-surface décor-synchronous formation of the structure 10 is provided.

[0139] FIG. 12 shows schematically that the structure 10 or the recess 13 on the top 11 of the layer composite 9 is visible both on the top 11 and, at least in some areas, on the bottom 12 of the layer composite 9. The depth 15 of the recess 13 may be greater than the height 16 of the protrusion 14 corresponding to the recess 13 on the bottom. Ultimately, not every recess 13 has to form a protrusion 14 on the bottom 12. In particular, for at least some recesses 13, it is provided that corresponding protrusions 14 can be formed on the bottom.

[0140] In FIG. 12, the depth 15 is schematically drawn and/or shown. It is not shown that the maximum depth 15 of the structure 10 is up to 1 mm, preferably between 0.05 mm to 0.2 mm.

[0141] The layered structure shown in FIG. 12 has a cured surface sealing layer 17, preferably formed as a lacquer layer, on the top 11 of the layer composite 9.

[0142] Also not shown is that the structure 10 on the bottom 12 of the layer composite 9 and/or the top layer 1 has/have a maximum height, or the protrusions 14 on the bottom 12 have a maximum height 16 of at most 100 μm.

[0143] The top layer 1 shown in FIG. 6 has a thickness 25 of at least 0.1 mm, in particular between 0.2 mm and 0.3 mm.

[0144] Not shown is that the base layer 4 is formed as a base film and/or a base foil.

[0145] Furthermore, it is not apparent from the embodiments shown that preferably the base layer 4 and/or the wearing surface 8 comprises and/or consists of a thermoplastic, preferably polypropylene, polyethylene and/or polyurethane, as the polyvinyl chloride-free material.

[0146] FIG. 15 shows a decking element 3. The decking element 3 may be intended for use as a floor, wall and/or ceiling covering element for a floor, wall and/or ceiling covering. The decking element 3 comprises a carrier plate 2 and a top layer 1 according to one of the preceding embodiments. The bottom 26 of the top layer 1 facing away from a usable side 7 is firmly connected to the top 27 of the carrier plate 2 facing the usable side 7, preferably connected over the entire surface.

[0147] It may also be provided, in further embodiments, that the bottom 26 is connected to the top 27 at least in certain areas.

[0148] Preferably, the top layer 1 has been laminated to the top 27 of the carrier plate 2.

[0149] FIG. 13 shows that corresponding tongue and groove connection geometries 28 are provided on opposite sides of the carrier plate 2, in particular for forming a click connection. The tongue and groove connection geometries 28 have a groove side 29 with a groove 30 and a tongue side 31 with a tongue 32. The groove side 29 is opposite the tongue side 31.

[0150] FIG. 15 shows that opposite sides of the longitudinal sides are formed as corresponding tongue and groove sides 29, 30.

[0151] Not shown is that opposite sides of the transverse sides are formed as corresponding tongue and groove sides 29, 30.

[0152] Not shown is that opposite sides of the carrier plate 2 have corresponding snap fastener and/or bayonet connection geometries.

[0153] FIG. 13 further shows that a countermove 34 is disposed on the bottom 33 of the carrier plate 2. In further embodiments, the countermove 34 may comprise a kraft paper, a cork layer and/or expanded polyolefin (XPO).

[0154] The carrier plate 2 shown in FIG. 13 is a HDF board. It is not shown that in further embodiments the carrier plate 2 can be a real wood layer and/or a MDF board.

[0155] Furthermore, it is not shown that the carrier plate 2 has a plastic as material and/or consists thereof, preferably polypropylene and/or polyethylene. It is particularly preferred that the carrier plate 2 is also free of polyvinyl chloride.

[0156] The carrier plate 2 shown in FIG. 13 has a layer thickness 35 of at least 2 mm.

LIST OF REFERENCE SIGNS

[0157] 1 Top layer [0158] 2 Carrier plate [0159] 3 Decking element [0160] 4 Base layer [0161] 5 Top from 4 [0162] 6 Décor [0163] 7 Usable side [0164] 8 Wearing surface [0165] 9 Layer Composite [0166] 10 Structure [0167] 11 Top of 9 [0168] 12 Bottom of 9 [0169] 13 Recesses [0170] 14 Protrusions [0171] 15 Depth from 13 [0172] 16 Height from 14 [0173] 17 Surface sealing layer [0174] 18 Elements from 6 [0175] 19 first adhesion promoter layer [0176] 20 Bottom of 4 [0177] 21 other adhesion promoter layer [0178] 22 Laminating agent [0179] 23 Top of 6 [0180] 24 Bottom of 8 [0181] 25 Thickness from 1 [0182] 26 Bottom of 1 [0183] 27 Top of 2 [0184] 28 Tongue and groove connection geometry [0185] 29 Groove Side [0186] 30 Groove [0187] 31 Tongue Side [0188] 32 Tongue [0189] 33 Bottom of 2 [0190] 34 Countermove [0191] 35 Layer thickness from 2