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CN110886463A - 包含陶瓷材料或天然石材的地板镶板 - Google Patents

包含陶瓷材料或天然石材的地板镶板 Download PDF

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Publication number
CN110886463A
CN110886463A CN201910099984.6A CN201910099984A CN110886463A CN 110886463 A CN110886463 A CN 110886463A CN 201910099984 A CN201910099984 A CN 201910099984A CN 110886463 A CN110886463 A CN 110886463A
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China
Prior art keywords
layer
floor panel
panel according
core layer
density
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Granted
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CN110886463B (zh
Inventor
托马斯·卢克·马丁·贝尔特
汤姆·范·波尔
斯万·伯恩
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Caina Funo Home (China) Co.,Ltd.
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Champion Link International Corp
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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Ceramic Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Dispersion Chemistry (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Wood Science & Technology (AREA)
  • Floor Finish (AREA)

Abstract

本发明涉及一种包含芯层和顶部层的层压件的地板镶板，所述芯层包含陶瓷或矿物材料和粘合剂以及第一对对置边缘，所述第一对对置边缘包含互补的耦接部分以便允许多个地板镶板彼此互联，所述顶部层包含陶瓷材料或天然石材，其中所述芯层的面对所述顶部层的一侧包含增强层，所述增强层的局部的密度比所述芯层的其余部分的密度更高。

Description

包含陶瓷材料或天然石材的地板镶板
技术领域
本发明涉及一种包含陶瓷材料或天然石材的地板镶板。
背景技术
根据本领域已知的传统方法安装的砖片(tile)通过砂浆或粘合剂来粘附到基体上。安装后，它们设置有勾缝剂(grout)(“勾缝”)以提供水密封表面，所述水密封表面甚至可以铺设和使用在具有积水或流水的环境例如浴室。砖片固有的对于温度和湿度波动的稳定性和耐受性使得勾缝的水密性能够持久。由于其具有防水性、美观性和稳定性的明显优点，这种通过勾缝剂进行砖片安装的传统方式的结果满足了某些需求。
然而，还很明显的是，砖片具有某些缺点：铺设砖片的方法相当耗时费力，并且只有专业人员才能完成。从下面地板的表面预处理和增强以支撑砂浆和砖片的总重量，到砖片的布局以及勾缝剂的涂覆，都需要专业的设备和技能。对于需要勾缝的安装来说，在砖片之间须留有预定的间距，最理想地，砖片间距具有均匀的宽度。该间距随后填充以具有选定颜色和材料的勾缝剂，例如砂浆或环氧树脂。添加这种勾缝剂给基体带来下述具体限制：至少最小重量承载能力和平整度。如果基体没有充分地预处理，那么勾缝剂或者甚至砖片可能在使用时破裂。一旦安装后，勾缝后的地板能够持久使用。砖片地板成为结构的一部分，移除它需要专门的重型设备，并可能损坏基体的其余部分。不可能对以这种方式安装的砖片重复使用或改装。
在硬面地板领域中已知的是，为地板例如层压件或PVC地板的芯提供有锁定机构。这种互锁镶板的安装称为“浮式”并且提供前所未有的便利，因此即使是非专业人士或家庭杂工也能安装和拆卸地板。为了消除砖片的缺点并且使其易于安装、移除和更换，已经提出还为砖片的边缘提供这种类型的锁定机构。然而，这是不可能的，因为砖片具有固有硬度和脆性。
因此，在美国专利7，442，423等文献中已经提出的是，为刚性基体提供由陶瓷、玻璃或石材砖片形成的硬面饰面板，并且为该基体提供锁定机构以便允许进行浮式安装。在此甚至提出了模拟勾缝，旨在提供传统的勾缝后的砖片那样的外观和感觉。然而，该现有技术提出的建议过于理论化，并且未能提供关于当实际实现这种产品时如何解决面临的实际挑战的细节。
首先，当所述芯不是绝对稳定时，砖片将在横向和竖直方向上运动，从而给安装带来应力。这种应力破坏了砖片勾缝的结构完整性，使得这种安装不适合在潮湿环境中使用。例如，根据北美层压地板协会的NALFA3.2层压件膨胀测试测量，如在US 7，442，423中建议的HDF材料的芯板当与潮气接触时膨胀或扩张高达15％，从而永久地破坏了该安装。没有为设想的基础提供可行的替代材料。此外，如本发明所示，尽管该发明提及“刚性且稳定的芯”，但是基体镶板在温度变化下仍将独立地改变尺寸。
在浮式地板行业中已知的是，提供基于诸如PP、PE、PVC、PU等聚合物的替代性基体而不是基于木质纤维素或木纤维的芯(例如，HDF或MDF)作为基础。这些替代性基体已知在本行业中是现成的替代品，通常与不同塑料层组合来用于设计制造的产品。例如，可以在层压和塑料地板行业中提供泡沫的低密度芯或高密度实心芯、普通基体。然而，在所述领域中提出的材料不适于预期目的，因为木质纤维素或植物基材料的物理特性是其在潮湿环境下移动，并且塑料的物理特性是其在温度波动的环境下移动。没有提供解决该问题的具体方法。
其次，尺寸变化也会给砖片本身带来应力。陶瓷、瓷器和石材砖片的抗弯强度使得轻微的应力可导致表面开裂(多个细小的裂缝)和断裂。为了说明，当粘接在2000kg/m3的4mm实心PVC基体上时，4.8mm大理石砖片在从23℃加热到60℃时显示出破裂，在生活环境中-例如在日光浴室中或窗户后面容易达到所述温度。
第三，现有技术声称重量小于顶部层的基体有利于运输、安装和环境。提出了将HDF用作基体，其均匀密度为约850kg/m3。由于陶瓷砖片(ceramic tile)的密度为约2200kg/m3，实心石材的密度为约2800kg/m3，瓷器的密度为约2400kg/m3或更高，与传统的实心石材或陶瓷砖片相比，可以实现重量显著地减小。然而，当与诸如HDF的均匀密度的基体结合时，陶瓷砖片的抗冲击和抗压痕性不足以支持商业或者甚至正常的住宅用途。当受到较大压力-特别是局部压力(例如高跟鞋产生的压力)时，砖片倾向于破裂或显示出裂纹，因为基体不能为顶部层提供足够的支撑-尤其是当顶部饰面板具有较薄的尺寸时。
缺少关于如何形成实用的稳定且刚性的芯的细节以及用于预期目的的可行结构。因此，目前市场上仍然没有可商购的产品，说明了所属领域的现有技术的缺点。
现有技术文献描述了在顶部层与芯层之间添加玻璃纤维层的实施方式。这主要意味着在顶部层断裂时提供一些安全性，而不是为了防止该顶部层断裂，也不是为了增加或提高芯层的稳定性。因为玻璃纤维层位于芯层外部而非内部，所以添加该层对稳定性的影响也是极小的。
发明内容
因此，本发明的目的是提供一种基体镶板，其消除了现有技术的至少某些缺点，或者至少提供了现有技术的有益且可行的替代方案。
因此，本发明的目的是提供一种包含MgO,Mg(OH)2、MgSO4、MgCl2、CaCO3作为陶瓷或矿物材料的芯层。这些优选材料由于湿气或温度波动而显示出较小的膨胀或收缩或者未显示出膨胀或收缩，为此，所述芯层的矿物或陶瓷含量优选为至少80％，并且在具有至少大约85％的矿物或陶瓷含量时可以获得较好结果。这些芯材料-不像塑料成分那样-既不知道也不认定-不利于人们的健康。众所周知，HDF含有大量的三聚氰胺脲甲醛，这是一种热固性树脂，由于这些树脂不可降解而引起对人类健康和环境的担忧，同时其废物管理将有害毒素释放到环境中；热塑性替代品同样会引发关于持续性方面的问题。
本发明提供了一种包含芯层层压件和顶部层的地板镶板，所述芯层的层压件包含陶瓷或矿物材料和粘合剂、第一对对置边缘，所述第一对对置边缘包含互补的耦接部分而允许多个地板镶板彼此相互耦接，所述顶部层包含陶瓷材料或天然石材，其中所述芯层的面对所述顶部层的一侧包含增强层，所述增强层的局部的密度比所述芯层的其余部分的密度更高。
具体实施方式
本发明随此为所述顶部层提供了额外的支撑。这种局部的较高密度改进了抗冲击性并防止了所述顶部层的断裂。该较高密度层能够可选地用玻璃纤维层进行增强，该玻璃纤维层局部包含在所述基体材料内并位于所述支撑层的顶部表面附近。当然也可以考虑具有相似物理特性的任何其他纤维层。
所述增强层可以解释为更高密度的顶部层或硬外壳层，所述顶部层或硬外壳层能够通过挤出工艺形成，其中所述顶部和/或底部表面通过冷却工艺来增加密度，或者能够以具有不同密度的浆料的形式分层地沉积到基体并且随后进行干燥，或者添加具有不同密度的层。优选地，其密度比所述芯的其余部分大至少5％，更优选地大10％以上，并且甚至更优选地大20％以上。
本发明随此提供了一种陶瓷砖片，所述陶瓷砖片的侧面上具有互锁机构，所述陶瓷砖片可以安装为浮式地板，所述浮式地板能够承受冲击、运输中的应力、湿度和温度的波动，并且适用于商业环境。
根据本发明，通常来说，厚度在1和10mm之间的顶部层根据本发明是优选的，并且厚度在2和10mm之间(优选地约6mm)的芯是优选的。8-15mm的总产品厚度是更优选的。8mm厚的基于MgO的板在湿度和温度的波动下获得了良好的稳定性结果，所述8mm厚的基于MgO的板的总体密度为1200kg/m3，在所述顶部表面附近具有2mm厚的密度为1600kg/m3的硬外壳并且用玻璃纤维网进行增强。当然可以将玻璃纤维更换成天然纤维以实现完全无塑料的构造，或者添加更多的增强层-例如在靠近所述镶板的底部表面处，以调节所述板的总体稳定性。可以通过施加至少一个增强玻璃纤维网来实现进一步的改进，但是优选地具有两个这样的层，其中第二个靠近所述镶板的底部表面-优选地整合在增强层中：在该实施方式中，已经证实在浸入水中24小时后，当根据NALFA3.2测量时，尺寸稳定性在长度和宽度方向上的膨胀限于0.03％，并且记录到厚度膨胀小于0.01％。23℃-60℃的膨胀率为0％，加热至80℃后的收缩率根据ISO23999测量时测量为0％。
所述互补的耦接部分尤其可以包含棘爪耦接件，即当两个砖片彼此接合时卡扣固定的耦接件。向芯中添加少量木质纤维素纤维为锁定机构添加了足够的弹性，以允许锁定件的平滑接合。然而，木质纤维素含量优选地小于15％，最优选地小于10％，以便避免在潮湿条件和霉菌或真菌问题下膨胀。当根据用于确定合成高分子材料抗真菌性的标准实施规程-ASTM G21测定时，获得了具有0级抗真菌性(无真菌生长)的令人满意的结果，其中木质纤维素含量为约9％。优选地，木质纤维素含量高于8％，以便耦接部分能获得足够的柔韧性，所述耦接部分需要弯曲以便卡扣。
在本领域中已知为芯层进一步提供了生物陶瓷材料涂覆层以便实现抗真菌和除臭效果。这是必要的，因为木质纤维素或植物基镶板对霉菌或真菌生长敏感。由于添加了用作真菌养分的乙烯基化剂(vinylizer)或增塑剂，基于塑料的基体也对霉菌或真菌生长敏感。当根据ASTM G21测试时，含有增塑剂的常规乙烯树脂或PVC地板评定约为1-2级真菌抗性(少量地生长有真菌)。本发明提出了一种矿物或陶瓷基体，其包含MgO、Mg(OH)2、MgSO4、MgCl2、CaCO3或具有类似特性的替代材料，或者甚至基本上由它们制成，因此当按照ASTMG21测试时，所述矿物或陶瓷基体具有0级的天然抗真菌性(没有真菌生长)。
在本发明的进一步实施方式中，所述顶部层的表面积小于所述芯层的表面积。当用这些镶板组装地板时，给出了勾缝剂的痕迹，所述痕迹由所述芯层的未覆盖且因此可见的部分形成。由于所述镶板的预制性质，所产生的间距是一致的并且易于维护。那么如果需要的话可以用砂浆或环氧勾缝剂对该间距进行勾缝，或者可以用基体作为模拟勾缝。在这种情况下，所述基体优选地在至少两侧上与所述顶部层齐平，其中在至少一侧上具有模拟勾缝。可以制造具有一定颜色的勾缝剂以获得美学效果，或者在制造过程中添加颜色，或者在勾缝剂的表面添加具有特定颜色的终饰材料。
在芯层的背离顶部层的一侧可以进一步存在额外的底层，所述底层具有声音阻尼特性。为此，可以认为低密度层具有至少85kg/m3的密度，优选地具有大于130kg/m3的密度，所述低密度层例如具有其中存在封闭或开放的泡孔的泡沫结构。该泡沫结构通常通过在熔体形成和硬化成最终形状之前添加发泡剂到熔体中而获得。本领域常见的是基本上由乙烯-乙酸乙烯酯、辐射交联聚乙烯或类似的替代材料如聚氯乙烯构成的发泡层。出于环境考虑，可以考虑选择天然物质例如软木层或者一层再生PET(聚对苯二甲酸乙二醇酯)。这种声音阻尼层的另一个益处是对基体不规则性的消减和整平，甚至进一步降低了顶部层断裂的可能性。

Claims (17)

1.一种适于组装地板或墙体覆盖装置的镶板，包含：
-芯层，其包含
陶瓷或矿物材料和粘合剂；
至少一对对置边缘，所述对的对置边缘包含互补的耦接部分，允许多个地板镶板彼此耦接；
-顶部层，其包含陶瓷材料、砖片、瓷器陶瓷、天然石材或马赛克；
其中，所述芯层的面向所述顶部层的一侧包含增强层，所述增强层的局部的密度与所述芯层的其余部分的密度不同。
2.根据权利要求1所述的地板镶板，其中所述增强层的密度高于所述芯层的其余部分。
3.根据权利要求2所述的地板镶板，其中所述增强层的密度比所述芯层的其余部分的密度高至少5％，更优选地高10％，最优选地高至少20％。
4.根据前述权利要求中任一项所述的地板镶板，包含位于所述增强层的表面附近的纤维网。
5.根据前述权利要求中任一项所述的地板镶板，其中所述增强层是硬外壳层。
6.根据前述权利要求中任一项所述的地板镶板，其中所述芯层的密度低于所述顶部层的密度。
7.根据前述权利要求中任一项所述的地板镶板，其中所述互补的耦接部分包含棘爪耦接件。
8.根据前述权利要求中任一项所述的地板镶板，其中所述芯层包含MgO、Mg(OH)2、MgSO4、MgCl2、CaCO3作为陶瓷或矿物材料。
9.根据权利要求7所述的地板镶板，其中所述芯层的矿物或陶瓷含量为至少50％，更优选地大于75％，最优选地为至少85％。
10.根据前述权利要求中任一项所述的地板镶板，其中所述芯层包含木质纤维素作为粘合剂，所述木质纤维素的含量尤其在8％至15％之间，更优选地为9％或10％。
11.根据前述权利要求中任一项所述的地板镶板，其中所述顶部层包含陶瓷、天然石材、石材饰面板、马赛克或瓷砖。
12.根据前述权利要求中任一项所述的地板镶板，其中所述顶部层的厚度为1至12mm，并且所述芯的厚度为2至10mm，优选地约为6至8mm。
13.根据前述权利要求中任一项所述的地板镶板，其中所述顶部层的表面积小于所述芯层的表面积。
14.根据前述权利要求中任一项所述的地板镶板，其中，在至少一侧上，所述芯层是可见的以便模拟勾缝。
15.根据前述权利要求中任一项所述的地板镶板，其中可以涂覆勾缝剂来实现防水安装。
16.根据前述权利要求中任一项所述的地板镶板，其中所述芯层的未被所述顶部层覆盖的至少一部分具有预先涂覆的终饰材料来模拟勾缝。
17.根据前述权利要求中任一项所述的地板镶板，其中所述芯层背离所述顶部层的一侧处具有底层，所述底层具有声音阻尼和整平的特性。
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