Method for producing a decorated wall, ceiling or floor panel
For simpler production of a waterproof, decorated wall, ceiling or floor panel with improved quality, the invention proposes a process involving the following steps: provision of a panel-shaped carrier and a non-woven fabric, application of an adhesive to one surface of the carrier or to a surface of the non-woven fabric, lamination of the non-woven fabric by means of the applied adhesive to the surface of the carrier, impregnation of the non-woven fabric with a liquid means, hardening of the impregnating agent, application of a sealing layer as a liquid composition and hardening of the sealing layer and/or application of a top layer as a liquid composition and hardening of the top layer.
1. Method for producing a decorated wall, ceiling or floor panel, comprising the steps of:
a) providing a plate-shaped carrier and a non-woven fabric;
b) applying an adhesive to a surface of the carrier or a surface of the non-woven fabric;
c) laminating the non-woven fabric by means of the applied adhesive to the surface of the carrier;
d) impregnating the non-woven fabric with an impregnation agent, wherein the impregnating is performed by a rubber roller which has a shore (A) hardness of 20 to 40 and the rubber roller protrudes from the carrier in the direction of the roller axis by at least 20 mm; and
e) curing the impregnation agent;
wherein the carrier is a plastic carrier and the non-woven fabric is a print base paper; and
printing a décor onto the paper between steps c) and d).
2. Method according to claim 1 , comprising the further process steps:
f) applying a wearing layer and curing the wearing layer; and/or
g) applying a top layer and curing the top layer.
3. Method according to claim 1 , characterized in that the non-woven fabric is a decorative paper.
4. Method according to claim 1 , characterized in that the adhesive is a hot melt adhesive.
5. Method according to claim 4 , characterized in that the hot melt adhesive is a reactive hot melt adhesive.
6. Method according to claim 1 , characterized in that the impregnation agent, the composition for producing the wearing layer and/or the composition for producing the top layer comprise components are adapted to be cross-linked by radiation and each curing step is implemented by means of electromagnetic radiation.
7. Method according to claim 1 , characterized in that the impregnation agent consists of at least two components and impregnating step (d) comprises successively impregnating the two components into the non-woven fabric.
8. Method according to claim 1 , characterized in that at least one of the compositions for the impregnation agent, the wearing layer or the top layer includes at least a polyester acrylate, an epoxy acrylate and a photoinitiator.
9. Method according to claim 1 , characterized in that the composition for producing the wearing layer includes particles of a solid with a Mohs hardness of at least 6.
10. Method according to claim 1 , characterized in that the impregnation agent, the composition for producing the wearing layer and/or the composition for producing the top layer include components adapted to be cross-linked by heat and the curing step is implemented by heating.
11. Method according to claim 1 , characterized in that the carrier is cut between steps c) and d), and the carrier is sealed watertightly at lateral surfaces.
12. Decorated wall, ceiling or floor panel produced by a method according to claim 1 .
13. Method according to claim 2 , characterized in that the impregnation agent, the composition for producing the wearing layer and/or the composition for producing the top layer comprise components adapted to be cross-linked by radiation and each curing step is implemented by means of electromagnetic radiation.
14. Method according to claim 2 , characterized in that the impregnation agent consists of at least two components and impregnating step (d) comprises successively impregnating the two components into the non-woven fabric.
15. Method according to claim 2 , characterized in that at least one of the compositions for the impregnation agent, the wearing layer or the top layer includes at least a polyester acrylate, an epoxy acrylate and a photoinitiator.
16. Method according to claim 1 , characterized in that the composition for producing the wearing layer includes particles of a solid with a Mohs hardness of at least 6.
17. Method according to claim 2 , characterized in that the impregnation agent, the composition for producing the wearing layer and/or the composition for producing the top layer comprise components adapted to be cross-linked by radiation and each curing step is implemented by means of electromagnetic radiation;
the impregnation agent consists of at least two components and impregnating step (d) comprises successively impregnating the two components into the non-woven fabric;
at least one of the compositions for the impregnation agent, the wearing layer or the top layer includes at least a polyester acrylate, an epoxy acrylate and a photoinitiator.
18. Method according to claim 15 , characterized in that the composition for producing the wearing layer includes particles of a solid with a Mohs hardness of at least 6.
19. Method according to claim 1 wherein the rubber roller protrudes from the carrier in the direction of the roller axis by between 20 mm and 100 mm.
20. Method according to claim 1 , characterized in that the impregnation agent consists of at least two components which are blended together before step (d) impregnating into the non-woven fabric.
21. Method according to claim 2 , characterized in that the impregnation agent consists of at least two components which are blended together before step (d) impregnating into the non-woven fabric.
22. Method according to claim 2 , characterized in that the impregnation agent, the composition for producing the wearing layer and/or the composition for producing the top layer comprise components adapted to be cross-linked by radiation and each curing step is implemented by means of electromagnetic radiation;
the impregnation agent consists of at least two components which are blended together before step (d) impregnating into the non-woven fabric
at least one of the compositions for the impregnation agent, the wearing layer or the top layer includes at least a polyester acrylate, an epoxy acrylate and a photoinitiator.