Method to manufacture floor panel with high antiskid properties

FIELD: construction.

SUBSTANCE: method to manufacture a floor panel (1), including a bearing board (2) and a decorative layer (3) applied onto the upper side of the bearing board (2), consists in the fact that the decorative layer (3) is pressed in a press with heat supply to the bearing board (2), besides, when pressing with the help of a stamping tool in th surface (8) of the decorative layer (3) a surface structure (10) is arranged, which serves to imitate a wood pattern or a different material. When pressing with the help of a stamping tool, microgrooves (9) are arranged in the surface (8) of the decorative layer (3), where a surface structure is imposed, also comprising grooves, which in their dimensions are much larger than microgrooves.

EFFECT: invention provides for antiskid properties of a panel.

8 cl, 2 dwg

 

The invention concerns a method of manufacturing a floor panel, comprising a carrier plate and deposited on the upper side of the carrier plate decorative layer.

The prior art floor panel with the bearing plate, which are made of wood chips or wood fibers with the addition of adhesives and/or resins by pressing in the press for wood-based panels, resulting in, for example, fibrous plates medium density (MDF boards) or fibrous plates of high density (HDF-plate). Typically, the carrier plate thus manufactured in a continuous process, and then cut out in a saw-setting.

The decorative layer includes, as a rule, sealed paper, which are impregnated with melamine resin and together with the upper layer or, respectively, the protective layer is pressed in a reduced state in a press under high temperature and pressure on the carrier plate. When napressovyvanie decorative layer on the carrier plate is obtained laminate plate, which is then split into separate floor panel.

In addition, the prior art method of performing using patterns stamping stamping tool, press in the decorative layer patterns to give the floor, which consists of floor panels, natural appearance. If the decorative layer is, for example, the R, to simulate a wooden floor, with a stamped hollow sealed under a tree decorative paper gives the impression of wood pores or texture of wood. For example, from WO 2001/096689 A1 or US 2002/0014047 A1 famous laminate panel with decorative paper under the tree, and decorative paper applied a transparent layer with grooves that almost passed the figure of a tree. From EP 1820574 known method of application roller for embossing for the application of surface structure on the panel.

In addition, from DE 19518270 C1-known anti-slip floor coating, the surface of which is made lenticular, with sharp edges, very shallow depressions. These microcrater should act like a vacuum to the suction cups by which the floor has a high anti-slip properties. Thus these microcrater performed in the surface of the flooring through targeted set of laser pulses. In the manufacture of floor panels, the decorative layer and the supporting plate which are pressed in the press, it would lead to an additional step of processing, which must be applied relatively expensive technology.

Therefore, the basis of the invention is to provide a method with which you can easily and inexpensively produce Napoli the s panels with high anti-slip properties.

Underlying the invention the task is solved by the combination of characteristics in claim 1. The preferred embodiments are contained in the dependent clauses.

A method of manufacturing a floor panel according to paragraph 1, characterized by the fact that during pressing by using a stamping tool, the surface of the decorative layer perform microglobuline. Stamping tool may be, for example, made as a stamping plate, a closed-loop tape or die-stamping roller.

In accordance with the invention, when the pressing using a pressing tool, for example, in the form of a stamping plate in addition to microglobuline on the surface of the decorative layer is applied to the superimposed surface structure. This imposed the surface structure in the floor panel, the decorative layer having wood patterns, simulated wood pores or texture of wood. This imposed the surface structure has recesses, which in size greatly outweigh microglobuline, which are provided with a high anti-slip properties. Of course, with a decorative layer superimposed with the surface structure it is possible to simulate and other materials (such as stone materials, which are known for tiles or the like).

From panasonicyouth surface of the decorative layer attached to the surface roughness. Depending on the size, distribution and shape of microglobuline when this occurs the structure, reminiscent of the surface structure of the grinding or abrasive paper. In the preferred embodiment, the neighboring microglobuline form a closed line, through which are formed a separate microwavecity. These separate microwavecity resemble in their principle of action of abrasive grain abrasive paper.

Preferably, the maximum depth of microglobuline less than 120 μm. Good results against anti-slip properties can be obtained by limiting the maximum depth of microglobuline to 90 μm, 50 μm, or even 20 microns.

The decorative layer may be made of a multilayer. For example, can be used decorative paper and at least one deposited a protective layer. This protective layer may include a curable resin, which preferably represents the amino. Preferred is the use of melamine resin and urea resin.

The protective layer may include crushed abrasive materials. Preferred are particles of minerals such as aluminium oxide particles or particles of corundum.

Along with a protective layer comprising powdered abrasive material and a curable resin may be provided in another layer, which is applied to the facing away from the decorative layer side of the protective layer. Due to this additional layer, which preferably contains the amino possible to reduce the wear of the forming plates, caused by the crushed abrasive materials, so using stamping plates can conduct a greater number of cycles pressing.

In particular, high anti-slip properties can be achieved in the absence provided an additional layer. In this case, the protective layer comprising powdered abrasive material forms the outer layer of the floor panel. Then microglobuline run directly in this layer, which may lead to the partial release of abrasive particles and their participation in the education part of the surface of the decorative layer. This leads to a structure resembling the structure of sandpaper or emery paper. The wear-resistant abrasive paper abrasive grains protrude from the binder, which separate the abrasive grain is connected with the base grit paper.

Stamping tool may have a hard coating, in which the structure of the embossing, which are obtained microglobuline. This hard coating preferably is a layer of chromium.

Preferred POS of the activity execution patterns stamping in the chrome layer is to first apply a layer that protects against etching, and then perform the etching process, the layer that protects against etching, protects a separate area of a hard coating of the removed material. Where etching tool can easily affect the hard coating or, respectively, the chrome layer, the material is removed, so that these locations are the indentations in the hard coating.

Preferably the total area of the layer that protects against etching is less than 50% of the area of pressing the forming tool. This means that in this example implementation removed more than half of the area of the chrome layer, due to which there exaltation, then when pressing in the press create microglobuline in the surface of the decorative layer of the floor panel. The layer that protects against etching, can be composed of many small dots, which in this case lead to a point elevations in the chrome layer. The total area of these points or, in General, a layer that protects against etching, may also take values less than 40 or even 30%.

Superimposed surface structure, which in the case of decoration under the tree can be simulated wood pores or wood texture can be obtained by using the superimposed patterns of engraving, and the superimposed structure of the stamping is done in located under paved the primary layer of the forming tool. This base layer, which, for example, can be made of stainless steel, can also be subjected to the etching process, and by applying a layer that protects against etching, it is possible to obtain the desired superimposed structure of the embossing. Upon completion of the imposed structure of the embossing is applied hard coating, which, in turn, is subjected to another etching process. Along with the etching process can also be applied to other processes material removal, for example by spark erosion or laser processing.

The invention is hereinafter explained in more detail with the help of the floor panel shown in the drawing. Shown:

figure 1 - schematic cross section of a floor panel;

and figure 2 - part of figure 1 on an enlarged scale.

1 schematically shows a cross-section of the floor panel 1. The floor panel 1 includes a carrier plate 2, which, for example, can be made of MDF or HDF boards. The carrier plate 2 can also be made of other materials.

On the carrier plate 2 with the upper hand applied decorative layer 3, which includes impregnated with melamine resin decorative paper 4 and protective layer 5. The protective layer 5 includes a variety of corundum particles 6, which are introduced in the matrix 7 of the melamine resin.

In the surface 8 of the decorative layer 3 vol is LINENO many microglobuline 9, which, in particular, also shown in figure 2. Figure 2 shows in enlarged scale marked II fragment figure 1.

In the surface 8 is, however, embossing not only microglobuline 9, but imposed surface structure, which is indicated by the dashed line 10. This imposed the surface structure 10 forms the recess 11 of larger size, which should mimic wood pores or wood texture. It should be noted that the dimensions of the recesses 11 is significantly greater than the dimensions of microglobuline 9. This concerns, on the one hand, the depth and size in the direction perpendicular to the depth of the respective recesses 9, 11.

Using microglobuline 9 surface 8 of the decorative layer attached to the surface roughness, so you can be ensured the best options anti-slip properties. When performing microglobuline 9 during the pressing surface 8 may at least partially be released separate corundum particles 6, so the surface 8 to the touch is similar to the surface of the grinding wheel or sandpaper.

Between two adjacent macroglobulinemia 9a, 9b (see figure 2) is formed microvasculara 12, which acts like an abrasive grain abrasive paper and thereby contributes greatly to the fact that the surface 8 to the touch a hundred is ulitsa similar to the surface of the abrasive paper. Due to the form of microglobuline 9, their number and their distribution, you can specify the shape, height, distance, and number of microwavemini 12, making it possible to purposefully regulate anti-slip properties of the surface 8. Microwavecity 12 may have a dot shape, almost circular in shape, or other shape.

The floor panel 1, as shown in figure 1, has a stabilizing layer 13, which is affixed to the bottom side of the carrier plate 2. Using a stabilizing layer 13 should be a good steady position on the plane and prevented buckling of the floor panel 1.

The list of items

1 Floor panel

2 Bearing plate

3 Decorative layer

4 Decorative paper

5, a Protective layer

6 Corundum particles

7 Matrix of melamine resin

8 Surface

9 Microglobuline

10 Superimposed surface structure

11 Time

12 Microvasculara

13 Stabilizing layer.

1. A method of manufacturing a floor panel (1)comprising a carrier plate (2) and put on the top side of the carrier plate (2) decorative layer (3), and a decorative layer (3) zapressovyvajut in the press with a supply of heat to the carrier plate (2), and when pressing using a stamping tool surface (8) of the decorative layer (3) perform surface structure 10), used for drawing imitation wood or other material, characterized in that during pressing by using a stamping tool surface (8) of the decorative layer (3) perform microglobuline (9)enhancing anti-slip properties, and these microglobuline impose surface structure also having grooves, which for its size is much more microglobuline.

2. The method according to claim 1, characterized in that the neighboring microglobuline (9) form a closed line, through which are formed a separate microwavecity (12).

3. The method according to claim 1, characterized in that the maximum depth of microglobuline less than 120 microns.

4. The method according to claim 1, characterized in that the decorative layer (3) includes decorative paper (4) and at least one protective layer (5).

5. The method according to claim 4, characterized in that the protective layer (5) includes abrasive materials in the form of particles.

6. The method according to claim 1, characterized in that the stamping tool supply hard surface, into which enter the structure of the embossing, which receive microglobuline (9).

7. The method according to claim 6, wherein the hard coating is a layer of chromium.

8. The method according to claim 6 or 7, characterized in that the superimposed surface structure (10) obtained using the superimposed patterns of tisani is, moreover, the imposed structure of the embossing is performed in located under paved the primary layer of the forming tool.



 

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