# US 10,479,134 B2 · Method for producing a decorated wall or floor panel

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- Number: US 10,479,134 B2
- Document ID: US10479134B2
- Status: Granted
- Kind: B2
- Application number: 15/310,017
- Filed: 2015-04-28
- Published: 2017-06-08
- Granted: 2019-11-19
- Earliest claimed: 2014-05-09
- Assignees: Akzenta Paneele + Profile GmbH
- Applicants: Akzenta Paneele + Profile GmbH
- Inventors: Hans-Juergen Hannig
- Web page: https://patentgrep.com/patent/US10479134B2

## CPC

- B44C 5/04: Ornamental plaques, e.g. decorative panels, decorative veneers
- B27N 3/24: characterised by using continuously acting presses having endless belts or chains moved within the compression zone
- B27N 7/005: {Coating boards, e.g. with a finishing or decorating layer}
- B29C 43/22: of articles of indefinite length
- B29C 43/48: Endless belts
- B30B 5/06: co-operating with another endless band
- E04F 13/00: Coverings or linings, e.g. for walls or ceilings (flooring E04F15/00; decoration of surfaces, mosaic work B44, e.g. paper-hanging B44C7/00; made of webs, e.g. of fabrics or wallpaper {, as such, or their manufacturing} D03D, D04G, D04H, D06N, D21H; construction of {false} ceilings E04B9/00; roofings or similar water-tight coverings against precipitation E04D)
- E04F 15/102: {of fibrous or chipped materials, e.g. bonded with synthetic resins}
- B29C 43/28: incorporating preformed parts or layers, e.g. compression moulding around inserts or for coating articles
- B29C 2043/483: {cooperating with a second endless belt, i.e. double band presses}
- B29L 2031/732: {Floor coverings (piles carpets B29L2031/7652; for vehicles B29L2031/3017)}
- B32B 37/20: involving the assembly of continuous webs only
- B32B 2471/00: Floor coverings (B32B2419/04 takes precedence)
- B32B 2607/00: Walls, panels
- B44C: PRODUCING DECORATIVE EFFECTS (processes for applying liquids or other fluent materials to surfaces, in general B05D; shaping of plastics or substances in a plastic state B29C; printing processes to produce transfer pictures B41M3/12; thermographic duplication or marking methods B41M5/00); MOSAICS; TARSIA WORK (imitation of mosaic or tarsia work patterns B44F11/04); PAPERHANGING {(labels G09F; multi-step processes for making paper labels or tags B31D1/02)}
- B27N: MANUFACTURE BY DRY PROCESSES OF ARTICLES, WITH OR WITHOUT ORGANIC BINDING AGENTS, MADE FROM PARTICLES OR FIBRES CONSISTING OF WOOD OR OTHER LIGNOCELLULOSIC OR LIKE ORGANIC MATERIAL (containing cementitious material B28B; shaping of substances in a plastic state B29C; fibreboards made from fibrous suspensions D21J; drying F26B17/00)
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- B30B: PRESSES IN GENERAL (producing ultra-high pressure or ultra-high pressure and high temperature to effect modifications of a substance, e.g. for making artificial diamonds B01J3/00 ){(compressing means for refuse receptacles B65F1/1405)}
- E04F: FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS (windows, doors E06B)
- B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM

## Abstract

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.

## Claims

### Claim 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.

### Claim 2 (depends on 1)

The method according to claim 1, wherein a carrier material on the basis of a plastic or a wood-plastic composite material is provided.

### Claim 3 (depends on 2)

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.

### Claim 4 (depends on 2)

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).

### Claim 5 (depends on 1)

The method according to claim 1, wherein the carrier material comprises hollow microspheres.

### Claim 6 (depends on 1)

The method according to claim 1, wherein the belt conveying means are at least partially structured.

### Claim 7 (depends on 1)

The method according to claim 1, wherein a sensor for checking the placement of the carrier material between the belt conveying means is provided.

### Claim 8 (depends on 1)

The method according to claim 1, wherein a fiber material, in particular a fiber material web, is incorporated in the carrier.

### Claim 9 (depends on 1)

The method according to claim 1, wherein a temperature gradient is set in method step c) or in method step e).

### Claim 10 (depends on 1)

The method according to claim 1, wherein method step c) is carried out by use of two plate-shaped forming means.

### Claim 11 (depends on 1)

The method according to claim 1, wherein method step d) is carried out by use of a S-roller.

### Claim 12 (depends on 1)

The method according to claim 1, wherein the belt-like conveying means each comprise a steel belt coated with polytetrafluorethylene.

### Claim 13 (depends on 1)

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.