Laminate product and method of making same

• US 20070218260A1
• Filed: 08/08/2005
• Published: 09/20/2007
• Est. Priority Date: 08/09/2004
• Status: Abandoned Application

• Current Assignee: Claude Campo, Elmar Beck, Jean-Jacques Strub, Mark Zierold, Thierry Miclo, Ulrich Zierold
• Original Assignee: Claude Campo, Elmar Beck, Jean-Jacques Strub, Mark Zierold, Thierry Miclo, Ulrich Zierold
• Inventors: Beck, Elmar, Campo, Claude, Miclo, Thierry, Strub, Jean-Jacques, Zierold, Ulrich, Zierold, Mark
• Application Number:
  US11/374,290
• Publication Number:
  US 20070218260A1
• Time in Patent Office: Days
• US Class Current: 428/211.100
• CPC Class Codes: B32B 21/02 the layer being formed of fibres, chips, or particles , e.g. MDF, HDF, OSB, chipboard, particle board, hardboard
• CPC Class Codes: B32B 21/06 of paper or cardboard
• CPC Class Codes: B32B 2260/028 Paper layer
• CPC Class Codes: B32B 2260/046 Synthetic resin
• CPC Class Codes: B32B 2266/0278 Polyurethane
• CPC Class Codes: B32B 2272/00 Resin or rubber layer comprising scrap, waste or recycling material
• CPC Class Codes: B32B 2307/10 having particular acoustical properties
• CPC Class Codes: B32B 2307/102 Insulating
• CPC Class Codes: B32B 2307/304 Insulating
• CPC Class Codes: B32B 2419/04 Tiles for floors or walls
• CPC Class Codes: B32B 2471/00 Floor coverings B32B2419/04 takes precedence
• CPC Class Codes: B32B 29/007 next to a foam layer
• CPC Class Codes: B32B 29/02 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 29/06 specially treated, e.g. surfaced, parchmentised
• CPC Class Codes: B32B 5/18 characterised by features of a layer of foamed material
• CPC Class Codes: B32B 7/10 at least one layer having inter-reactive properties
• CPC Class Codes: B32B 7/14 applied in spaced arrangements, e.g. in stripes
• CPC Class Codes: E04F 15/02 Flooring or floor layers composed of a number of similar elements of webs E04F15/16
• CPC Class Codes: E04F 15/181 Insulating layers integrally formed with the flooring or the flooring elements
• CPC Class Codes: E04F 15/206 Layered panels for sound insulation
• CPC Class Codes: E04F 2290/043 : with a bottom layer for sound insulation
• CPC Class Codes: Y10T 428/24934 : including paper layer
• CPC Class Codes: Y10T 428/249953 : Composite having voids in a component [e.g., porous, cellular, etc.]
• CPC Class Codes: Y10T 442/693 : Including a paper layer

Abstract

Laminated floorboards with sound damping in a less complicated manner. For this purpose, a compensating element, is provided in which an impregnated paper is joined to an insulating underlay. By means of the use of the compensating element in a laminated floorboard, in which the insulating underlay is used as a sound-damping material layer, in particular using an adhesive coating between paper and underlay, a halving of the sound pressure as compared with a standardized reference floor construction can be demonstrated in a footfall test. A series of process engineering, environmentally friendly and logistical advantages are associated with the use of the process and apparatuses according to the invention for production of compensating element and laminated floorboard, such as the omission of specific fabrication steps, a reduced use of formaldehyde and the ability to use simplified transport apparatuses.

Claims

1. A compensating element, in the form of an impregnated backing, for laminated floorboards comprising an impregnated paper, wherein the impregnated paper is joined to an insulating layer.

2. The compensating element as claimed in claim 1, wherein the impregnated paper is joined to the insulating layer by means of and impregnant of the paper.

3. The compensating element as claimed in claim 1, wherein the insulating layer is formed of a sound-damping material layer and is applied to the impregnated paper by means of an adhesive coating.

4. The compensating element as claimed in claim 1, wherein the impregnated paper is joined to the insulating layer by means of the attractive action in the presence of electrostatic charging.

5. The compensating element as claimed in claim 3, wherein the sound-damping insulating layer is comprised of one or more materials of the group including cork, pressed wood chips with a low density, felt, or compositions formed by using synthetic fibers, such as woven fabrics, nonwoven fabrics or films, of form, of granulated rubber or paperboard.

6. The compensating element as claimed in claim 5, wherein the foam is formed of polyurethane.

7. The compensating element as claimed in claim 6, wherein the polyurethane foam consists of recycled polyurethane foam, composite polyurethane foam and binder.

8. The compensating element as claimed in claim 3, wherein the adhesive coating consists of a hot-melt adhesive, a contact adhesive or an emulsified adhesive based on a copolymer.

9. The compensating element as claimed in claim 1, wherein the impregnated paper consists of a kraft paper.

10. The compensating element as claimed in claim 8, wherein the adhesive coating is formed by at least two adhesive tracks running in parallel.

11. The compensating element has claimed in claim 3, wherein the thickness of the sound-damping insulating layer, is 2 to 4 mm.

12. The compensating element as claimed in claim 6, wherein the polyurethane foam layer has a density of 200 to 400 kg/m³.

13. The compensating element as claimed in claim 1, wherein the paper is formed as recycled paper based on superior chemical pulps or as soda kraft paper and with base paper weight of 70 to 140 g/m².

14. The compensating element as claimed in claim 1, wherein impregnation of the paper is formed from one or more of an aminoplastic resin comprising urea and/or melamine resins, the final weight of the paper following impregnation and drying being 170 to 320 g/m².

15. A laminated floorboard, in the form of a flooring laminate, comprising a supporting board which is coated on an upper side and is provided on an underside with a compensating element, in the form of an impregnated backing, wherein the compensating element, having an impregnated paper joined with an insulating layer in the form of a sound-damping layer joined by means of an adhesive coating, the compensating element is joined to the supporting board, the insulating layer forming the lowest layer of the composite.

16. The laminated floorboard as claimed in claim 15, wherein the compensating element is joined to the supporting board by means of the impregnated paper by pressing.

17. The laminated floorboard as claimed in claim 15, wherein the supporting board consists of an HDF, MDF, chipboard or recycled board.

18. The laminated floorboard as claimed in one claim 15, wherein a coating of an impregnated decorative paper and an overlay lying over the decorative paper is arranged on the upper side of the supporting board.

19. A process for production of a compensating element, in particular an impregnated backing, wherein impregnated paper brought to a predefined dimensioned in paper blanks is stacked to form a paper stack, in each case a paper blank is lifted off the stack upper side and its deposited on a web of insulating material matched to the dimensions of the paper blank, the side of the web of insulating material that faces the paper to be deposited being provided with an adhesive layer before the deposition of the paper blank.

20. The process as claimed in claim 19, wherein the web of insulating material is unwound from a roll of insulating material and is pulled over a supporting surface until the section of the web of insulating material resting on the supporting surface has at least the length of the paper blank be deposited, the web of insulating material being held in the unwound position during the deposition of the paper blank.

21. The process as claimed in claim 20, wherein the paper blanks are fed to the web of insulating material from one or two paper stacks said paper stacks being arranged on one or both sides of the supporting surface in relation to a haul-off direction of the web of insulating material.

22. The process as claimed in claim 20 wherein, following the deposition of the paper blank, the fixed web of insulating material is cut to length in accordance with the length of the paper blank, forming a blank of the compensating element.

23. The process as claimed in claim 22, wherein, after the web of insulating material has been cut to length, the blank of the compensating element, is in each case lifted off the supporting surface and stacked to form a stack, the paper in each case forming the upper side of the stack.

24. The process as claimed in claim 23, wherein the blank of the compensating element, is stacked on a stack preferably placed on a pallet, said stack being arranged beside or behind the supporting surface in relation to a haul-off direction (X) of the web of insulating material.

25. The process as claimed in claim 20, wherein the application of the adhesive layer is carried out as the web of insulating material is unwound from the roll of insulating material.

26. The process for production of a compensating element, in particular an impregnated backing, wherein the impregnated backing paper and an insulating underlay in the form of a sound-damping material layer, are in each case pulled off rolls in the form of webs and are subsequently pressed against each other in an arrangement lying one above the other, before the pressing the adhesive coating being applied to the insulating underlay, in particular the sound-damping material layer, on its side facing the backing paper web.

27. The process as claimed in claim 26, wherein the bonded backing paper web and the web of insulating material formed from the insulating underlay are pulled off until the desired length of the impregnated backing is reached, the haul-off speed is then stopped, the impregnated backing is cut to length and then transported onward to be stacked.

28. An apparatus for production of a compensating element for laminated floorboards, which comprises a supporting apparatus which has a supporting surface for a web of insulating material and on which at one end there is arranged an unwinding device for unwinding the web of insulating material from a roll of insulating material, by a crosscutter arranged after the unwinding device in the haul-off direction (X), a gripping device which can be displaced in and counter to the haul-off direction (X) along the supporting apparatus for the web of insulating material, and at least one lifting, depositing and transport apparatus arranged above the supporting surface for the transport of an impregnated paper blank and/or a compensating element blank transversely with respect to the haul-off direction (X).

29. The apparatus as claimed in claim 28, wherein an adhesive applicator for applying an adhesive coating to the web of insulating material is arranged above the supporting surface immediately after the crosscutter in the haul-off direction (X).

30. The apparatus as claimed in claim 28, wherein the lifting, depositing and transport apparatuses is guided such that it can be displaced between two portal carriers arranged transversely, in particular at right angles, to the haul-off direction (X) and parallel to each other, on horizontal carrier sections and can be moved independently of each other.

31. The apparatus as claimed in claim 28, wherein there are two transport apparatuses, of which at least one transport apparatus (31, 31a), preferably both transport apparatuses, are assigned to the transport of the paper blanks and, if appropriate, the second transport apparatus is assigned to the transport of the impregnated backing blanks.

32. The apparatus as claimed in claim 31, wherein the transport apparatus for the paper blanks comprises suckers pressure strips which are fixed to a common transport frame and can be lifted and lowered, their contact surfaces for the paper blanks lying in a common plane.

33. The apparatus as claimed in claim 31, wherein the transport apparatus for the impregnated backing blanks comprises a plurality of vacuum suckers which can be lowered and lifted and whose contact surfaces for the impregnated backing blanks lie in a common contact plane.

34. The apparatus as claimed in claim 32, wherein the suckers are arranged in such a way and the suckers and the pressure strips are distributed in such a way that smooth lifting and lowering of the paper blanks is carried out.

35. The apparatus as claimed in claim 28, wherein the unwinding device has a drive motor to drive the roll of insulating material, the unwinding speed of the drive motor and the displacement speed of the gripping device being coordinated with each other.

36. The apparatus has claimed in claim 28, wherein the gripping device that can be displaced along the supporting apparatus in and counter to the haul-off direction (X) is guided on a guide strip.

37. The apparatus as claimed in claim 36, wherein the guide strip for the gripping device is adjoined by a guide rod which goes beyond the supporting surface in the haul-off direction (X).

38. The apparatus as claimed in claim 28, wherein a lifting table to accommodate a stack of impregnated backing components is arranged after the supporting surface in the haul-off direction (X).

39. The apparatus as claimed in claim 28, wherein, in order to convey the impregnated paper blanks and/or the impregnated backing blanks in and out, standby spaces and/or at least one storage space are provided, from or to which the stacks of impregnated paper blanks and the impregnated backing blanks are transported with the aid of transverse conveyors or longitudinal conveyors.

40. A process for production of at laminated floorboard, wherein in order to obtain a compensating element, in the form of an impregnated backing a compensating film, in the form of impregnated paper is fixed to the insulating underlay and, after that, the composite formed in this way is laid on aids, then a/the supporting board as a core consisting of wooden material, a decorative layer preferably formed by a/the decorative paper, in particular impregnated with melamine resin, and the overlay are laid successively on the composite and, finally, the whole formed by these aforementioned layers is gripped, placed in a pressing apparatus and pressed.

41. The process as claimed in claim 40, wherein the impregnated backing, is gripped, held and moved by using gripping means based on the action of vacuum, such as suckers.

42. The process as claimed in claim 40, wherein the pressing is carried out under a pressing pressure of 20 to 40 bar at pressing temperatures of 160 to 200°

C. and pressing times of 10 to 30 s.