Method for producing an abrasion- and water-resistant multilayer panel and a panel which is produced using said method

Abstract

It is provided a method for producing an abrasion- and water-resistant multilayer panel, in particular an abrasion- and water-resistant flooring panel, including the steps: providing at least one plastic carrier plate, in particular a PVC carrier plate; applying at least one base coat to the surface of the plastic carrier plate; printing the plastic carrier plate by direct printing to form a decorative layer; applying at least one first cover layer to the printed decorative layer; uniformly scattering abrasion-resistant particles onto the at least one cover layer applied to the decorative layer; applying at least one second covering layer to the layer of scattered abrasion-resistant particles; optionally, introducing a structure into the at least second cover layer, applying at least one lacquer layer, and curing the layer structure.

Claims

1. A method of manufacturing an abrasion and water resistant multilayer panel comprising the steps of: providing at least one polyvinyl chloride (PVC) carrier plate; applying at least one base coat comprising at least one polyurethane hot melt adhesive to a surface of the PVC carrier plate; applying at least one white base coat on top of the at least one base coat; direct printing of the PVC carrier plate with a formation of a decorative layer; applying at least one first cover layer comprising a polyurethane hot melt adhesive to the decorative layer, wherein the amount of the polyurethane hot melt adhesive of the at least one first cover layer is 20 and 50 g/m.sup.2; uniformly scattering a layer of abrasion-resistant particles onto the at least one first cover layer applied to the decorative layer; applying at least one second cover layer comprising a polyurethane hot melt adhesive to the layer of scattered abrasion resistant particles, wherein the amount of the polyurethane hot melt adhesive of the at least one second cover layer varies depending on the amount of the polyurethane hot melt adhesive of the first cover layer and is 20 and 50 g/m.sup.2; introducing a structure into the at least one second cover layer; applying at least one lacquer layer to the at least one second cover layer; and curing the layer structure, wherein the polyurethane hot melt adhesive is applied as the first cover layer and the second cover layer at an application temperature of around 150 C.

2. The method according to claim 1, wherein the surface of the PVC carrier plate is pretreated before printing to improve adhesion of subsequent layers.

3. The method according to claim 1, wherein the at least one base coat applied to the surface of the PVC carrier plate before printing comprises at least one primer layer.

4. The method according to claim 1, wherein the at least one white base coat is applied to the at least one base coat by digital printing.

5. The method according to claim 1, wherein the at least one decorative layer is applied by digital printing.

6. The method according to claim 1, wherein particles of corundum (aluminum oxides), boron carbides, silicon dioxides, silicon carbides are used as abrasion-resistant particles.

7. The method according to claim 1, wherein the at least one lacquer layer comprises a UV top lacquer.

8. The method according to claim 1, further comprising providing a lockable tongue-and-groove joint at at least two opposite edges of the panel.

9. The method according to claim 1, wherein the panel is an abrasion and water resistant floor panel.

10. The method according to claim 1, wherein the amount of the polyurethane hot melt adhesive of the first cover layer is 30 and 40 g/m2.

11. The method according to claim 1, wherein the amount of the polyurethane hot melt adhesive of the second cover layer is 30 and 40 g/m2.

12. The method according to claim 2, wherein the pretreatment is a grinding operation.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The solution is explained in more detail below with reference to the FIGURE in the drawings, using an example of an embodiment.

(2) FIG. 1 shows a schematic representation of a production line of a multilayer panel according to one embodiment of the method according to the solution.

DESCRIPTION OF THE INVENTION

(3) The production line shown schematically in FIG. 1 comprises a first section 1 for producing the plastic carrier plate and a second section 2 for surface processing the plastic carrier plate.

(4) Subsection 1 initially comprises a storage container 10 for PVC powder and a storage container 11 for limestone, which are mixed together in the mixing device 13 with the addition of further auxiliary materials 12.

(5) This powdered mixture of PVC, limestone (or chalk) and further additives can be temporarily stored in an intermediate hopper 14. The intermediate hopper 14 is arranged downstream of the mixing device in the processing direction. The extruder 15 is connected to the intermediate hopper 14 in the processing direction.

(6) As already discussed, a compound made from the individual components in pellet form can also be used directly as the starting component for extruder 15. In this case, storage tanks 10, 11, 12, mixing device 13, and intermediate hopper 14 can be dispensed with.

(7) The mixture (powder or compound) is fed into the extruder device 15 and pressed through a profile to form a continuous strand (SPC strand). The extruder device 15 is designed as a multi-stage extruder with zones of different temperature, with partial cooling with water. A sheet-like strand (e.g. with a maximum width of 1,400 mm) is discharged from the extruder via a slot die onto a roller conveyor 16, cut to size and stacked.

(8) Subsection 2 for the surface treatment of the plastic carrier plate starts with a separation and pre-treatment of the carrier plates, such as grinding (not shown).

(9) In a next step, at least one white-pigmented PUR hot melt is applied as a base coat to the surface of the plastic carrier plate using a roller unit 20.

(10) In the embodiment shown in FIG. 1, this is followed by a digital printer 21 for applying a white background, followed by one or more digital printers 22 for printing the decorative layer. The decorative printing is carried out according to the inkjet principle in a single-pass process in which the entire width of the top side to be printed is covered, with the plates being moved under the printer.

(11) The at least one device provided downstream of the printer 22 in the processing direction for applying a hot coating (PUR hot melt) as a first cover layer to the decorative layer is designed as a roller application device 23.

(12) Downstream of the roller application device 23 for the first cover layer, a first scattering device 24 is provided for uniformly scattering the abrasion-resistant material, such as corundum, on the upper side of the plastic carrier plate. The abrasion-resistant material used is corundum F220, which measures about 45-75 m in diameter according to FEPA standards.

(13) The scattering device 24 essentially consists of a supply hopper, a rotating, structured spiked roller and a scraper. The application quantity of the material is determined by the rotational speed of the spreader roller. Depending on the required abrasion class of the product, between 12-25 g/m.sup.2 of corundum is spread onto the board (AC4 (according to DIN EN 16511)=20 g/m.sup.2). From the spiked roller, the corundum falls at a distance of 5 cm onto the panel provided with the decorative foil.

(14) The scattering device 24 is followed in the processing direction by the device 25 for applying a hot coating as a second cover layer. Here, too, a PUR hotmelt is used as the hotcoating.

(15) The final lacquer layer is also applied using a roller device 27.

(16) A textured roller 26 is provided between the device 25 for applying the second cover layer and the roller device 27 for applying the final lacquer layer.

(17) The application devices are followed in the processing direction by devices for curing the layer structure, such as dryers and/or radiators (not shown). Suitable cooling devices and cutting devices are provided for further finishing (not shown).