Method for producing a decorated wall or floor panel
A method for producing a decorated wall or floor panel comprises providing a pourable carrier material, placing the carrier material between two belt-like conveying means, forming the carrier material under the action of temperature to form a web-shaped carrier, compressing the carrier, treating the carrier under action of pressure using a twin belt press, wherein the carrier is cooled within or upstream of the twin belt press, optionally cooling the carrier, optionally applying a decorative subsurface onto at least a portion of the carrier, applying a decoration reproducing a decorative template onto at least a portion of the carrier, applying a protective layer onto at least a portion of the decoration, optionally structuring the protective layer in order to introduce pores and/or the edge region of the carrier in order to form connecting elements, and optionally treating the carrier for electrostatic discharge prior to any one of the above steps.
1. A method for producing a decorated wall or floor panel, comprising at least the method steps performed in subsequent order:
a) providing a pourable granulate carrier material;
b) placing the carrier material between two belt conveying means;
c) heating the carrier material to a temperature above the melting point or softening point of the carrier material in order to form a web-shaped carrier;
d) compressing the carrier;
e) treating the carrier under the action of pressure by use of a twin belt press, wherein the carrier is cooled within or upstream of the twin belt press;
g) applying a decorative subsurface onto at least a portion of the carrier;
h) applying a decoration reproducing a decorative template onto at least a portion of the carrier;
i) applying a protective layer onto at least a portion of the decoration; and
j) optionally structuring the protective layer in order to introduce pores and/or the edge region of the carrier in order to form connecting elements.
2. The method according to claim 1 , wherein a carrier material on the basis of a plastic or a wood-plastic composite material is provided.
3. The method according to claim 2 , wherein a carrier material based on a WPC material comprising wood and polyethylene, wood and polypropylene or wood and a copolymer of polyethylene and polypropylene or based on a PVC material is provided.
4. The method according to claim 2 , wherein the carrier is cooled below the melting point or the softening point of the plastic component in method step e).
5. The method according to claim 1 , wherein the carrier material comprises hollow microspheres.
6. The method according to claim 1 , wherein the belt conveying means are at least partially structured.
7. The method according to claim 1 , wherein a sensor for checking the placement of the carrier material between the belt conveying means is provided.
8. The method according to claim 1 , wherein a fiber material, in particular a fiber material web, is incorporated in the carrier.
9. The method according to claim 1 , wherein a temperature gradient is set in method step c) or in method step e).
10. The method according to claim 1 , wherein method step c) is carried out by use of two plate-shaped forming means.
11. The method according to claim 1 , wherein method step d) is carried out by use of a S-roller.
12. The method according to claim 1 , wherein the belt-like conveying means each comprise a steel belt coated with polytetrafluorethylene.
13. The method according to claim 1 , wherein the carrier comprises a plastic material and the carrier subsequently to method step e) is heated to a temperature above the crystallization temperature of the plastic material present in the carrier.