CN100359116C - 地板系统和形成该地板系统的层压地板块 - Google Patents

地板系统和形成该地板系统的层压地板块 Download PDF

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CN100359116C
CN100359116C CNB038064510A CN03806451A CN100359116C CN 100359116 C CN100359116 C CN 100359116C CN B038064510 A CNB038064510 A CN B038064510A CN 03806451 A CN03806451 A CN 03806451A CN 100359116 C CN100359116 C CN 100359116C
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floor
board block
sandwich layer
floor board
layer
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CN1643226A (zh
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D·佩尔万
T·佩尔万
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Valinge Innovation AB
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    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/02—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions
    • B32B3/06—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions for securing layers together; for attaching the product to another member, e.g. to a support, or to another product, e.g. groove/tongue, interlocking
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23C—MILLING
    • B23C3/00—Milling particular work; Special milling operations; Machines therefor
    • B23C3/28—Grooving workpieces
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    • B27F—DOVETAILED WORK; TENONS; SLOTTING MACHINES FOR WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES
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    • B27F1/06—Making tongues or grooves, of indefinite length simultaneously along opposite edges of a board
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
    • B27M—WORKING OF WOOD NOT PROVIDED FOR IN SUBCLASSES B27B - B27L; MANUFACTURE OF SPECIFIC WOODEN ARTICLES
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    • E04F15/04—Flooring or floor layers composed of a number of similar elements only of wood or with a top layer of wood, e.g. with wooden or metal connecting members
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
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    • E04F2201/0107—Joining sheets, plates or panels with edges in abutting relationship by moving the sheets, plates or panels substantially in their own plane, perpendicular to the abutting edges
    • E04F2201/0115—Joining sheets, plates or panels with edges in abutting relationship by moving the sheets, plates or panels substantially in their own plane, perpendicular to the abutting edges with snap action of the edge connectors
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    • E04F2201/025—Non-undercut connections, e.g. tongue and groove connections with tongue and grooves alternating transversally in the direction of the thickness of the panel, e.g. multiple tongue and grooves oriented parallel to each other
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16B—DEVICES FOR FASTENING OR SECURING CONSTRUCTIONAL ELEMENTS OR MACHINE PARTS TOGETHER, e.g. NAILS, BOLTS, CIRCLIPS, CLAMPS, CLIPS OR WEDGES; JOINTS OR JOINTING
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    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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  • Wood Science & Technology (AREA)
  • Mechanical Engineering (AREA)
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Abstract

本发明公开了包括一对层压地板块的地板系统，每个地板块具有芯层、装饰表面层、以及一对连接装置，该连接装置用于使两个地板块沿水平方向彼此连接，其中当两个地板块连接时，在两邻接接头边缘之间获得装饰连接部，表面层上最靠近邻接接头边缘的部分形成水平面，其特征在于，装饰表面层是直接布置在芯层上侧和直接层压在其上的浸渍有三聚氰胺的装饰纸，以便芯层的最靠近装饰纸的上部部分浸渍有三聚氰胺；并且，仅每个地板块的成对边缘中的一个具有由芯层的最靠近表面层的浸渍有三聚氰胺的上部部分组成的表面，该表面与水平面成大约0-10度，并且形成为可见的以便构成在地板块连接时的装饰连接部。本发明还涉及形成地板系统的层压地板块。

Description

地板系统和形成该地板系统的层压地板块
技术领域
本发明一般涉及地板的装饰槽领域。本发明涉及设有装饰槽的地板(地板块)和制造该地板的方法。本发明特别适用于与WO9426999、WO9966151、WO9966152、SE0100100-7和SE0100101-5(为Vlinge Aluminium AB拥有)中公开的地板成一体的机械锁定系统，但是其还能在用于连接地板的任意连接系统中使用。
特别是，本发明首先涉及一种具有芯层(基材层)和在芯层上侧的装饰面层的地板。
本发明特别适用于由用与地板成一体即在工厂安装的连接系统以机械方式连接起来的地板构成的浮式地面/地板(floating floor)，其由一层或多层最好是防潮的装饰层或装饰塑料材料上层、中间基于木纤维的材料或塑料材料芯层和优选的在芯层背面的下平衡层组成。以下对现有技术描述中，已知系统的问题和本发明的目的和特点作为非限制性实例将针对于该申请领域特别是层压地板(laminate flooring)领域，该地板形成为待以机械方式由长侧和短侧连接的矩形地板。但是，应该强调的是，本发明用于具有任意连接系统的任意地板，其中地板最好具有一芯层和至少一表面层，这两部分具有或通过加工能够获得的颜色、图案、结构或类似形式的不同装饰特性。本发明因此还能够适用于例如具有一层或多层表面层的地板，该表面层由木材、塑料、柔性纤维如针刺毡或不同材料组合而成，这些不同材料包括木材、塑料、软木、橡胶或其它用作地板表面层的其它材料。本发明还可用于形成均匀材料如均匀木制地板中的装饰接头部。
背景技术
层压地板通常由6-9mm的纤维板芯层、0.2-0.8mm厚的层压上装饰表面层和0.1-0.6mm厚的由层压板、塑料、纸或类似物构成的下平衡层构成。表面层使地板美观耐用。芯层提供稳定性，而平衡层板使板在一年中的相对湿度(RH)改变时保持平坦。层压地板还能够由压缩层压板制成。表面层和平衡层适用于酚浸渍的牛皮纸或酚浸渍的木纤维芯层。当加压和加热时制造表面层、芯层和平衡层。地板块通常浮式铺设在而不是粘结在已有底层地板上，该底层地板不必完全平坦或水平。通过设置在地板块和底层地板之间的板或泡沫等形式的基材完全或部分消除任何不规则性。这种浮式地板中的传统硬地板通常通过在长侧和短侧上粘结的榫舌-槽接头(即接头包括一地板块上的榫舌或邻接地板块上的槽)来连接。当铺地板时，将这些板水平放置在一起，由此将沿一块板接合边缘的凸出榫舌插入到沿着邻接板接合边缘的榫舌槽内。在长侧和短侧使用同一方法。
除了在这种通过粘结的榫舌和槽接头连接的传统地板外，最近已经研制出不需要使用胶而是通过所谓的机械接头系统而以机械方式连接的地板。这些系统包括沿水平和/或垂直方向锁定板的锁定装置。通过加工(切削)板的芯层而形成机械接头系统。另外，锁定系统的部分可以由与地板成一体的单独材料构成，即使在加工中该单独材料也与地板连接。该单独材料可以通过机械方式、粘结和类似方式固定在地板上。其还可以机械式固定成使其能够沿接头边缘移置/移动或通过有角度的运动而将其卸下。
带机械接头系统的浮式地板的主要优点是，通过沿接头边缘的内斜、咬接和移置的各种组合，能方便而迅速地铺设地板。可以通过水平、垂直或在不同角度的移置而实现咬接。地板还可以被方便地揭起而在不同场所再次使用。机械接头系统的另一优点是，地板的边缘部可以由不需要具有良好粘结特性的材料制成。
最常用的芯层材料是具有高密度和良好稳定性的纤维板，通常称为HDF-高密度纤维板。有时也采用MDF-中密度纤维板作为芯层。通常，这些芯层材料具有高的品质，而且常常具有抗潮湿的美观表面。
通常在芯层上应用大约1-4mm厚的木制表面层，芯层由纤维方向垂直于表面层的纤维方向的木块构成。当表面层很厚而且表面层是0.2-1.0mm厚的薄单板时，也可使用刨花板、纤维板或胶合板/宝丽板(polywood)。
通过将表面层和平衡层施加在芯层材料上，可制成表面层为塑料、木材、单板、软木和类似物的层压地板和许多其它地板。当纤维板具有在一其中在高压和高温下压缩多片浸渍纸片的单独操作中制成的装饰性高压叠层(层压板，laminate)时，可以通过粘结预先加工好的装饰层而实现这一施加。但是，当前制造层压地板时最普通的方法是直接层压，其基于更新的原理，其中在一个相同步骤中完成装饰叠层的制造和固定于纤维板。浸渍纸片直接放置到板上并在高温高压下压制在一起，而不进行任何粘结。
除了这两种方法外，使用多种其它方法来提供具有表面层的芯层。装饰性图案可以印制在芯层的表面。接着在该表面上覆盖耐磨层。芯层还可以具有由木材、单板、装饰纸或塑料片制成的表面层，接着可用耐磨层覆盖这些材料。
通常，由上述方法获得很大的板形地板构件，接着将其锯切成几十个预制地板(floor panel)，然后将其加工成地板。上述方法在有些情况下可以获得制成的预制地板，而在进行获得成品地板的加工前不必接着进行锯切。通常在预制地板具有木表面层或单板表面层时，进行单个预制地板的加工。
在所有情况下，上述预制地板是沿其边缘单独加工成地板的。在高级铣床中完成边缘的加工，其中预制地板精确定位在安装的一条或多条链条和皮带之间，使得预制地板能够高速并以很高精度通过多个铣削电动机，这些铣削电动机上设有金刚石切割刀具或金属切割刀具以用于加工预制地板的边缘。通过使用以不同角度工作的几个铣削电动机，能够以超过100米/分钟的速度和±0.02mm的精度形成高级的接头几何结构。
术语的定义：
在下文中，已安装地板的可见/暴露表面称为“前面”，而地板的相对侧，即面对底层地为一侧，称为“背面”。使用的片形原始材料称为“芯层”。当芯层覆盖有最靠近前侧的表面层和优选地最靠近背面的平衡层时，则其形成半成品，称为“预制地板”，或如果在随后的操作中该半成品被分成多个上述预制地板，则称为“地板构件”。当沿预制地板的边缘对其加工以便获得其具有接头系统的最终形状时，将其称为“地板”。“表面层”表示最靠近前面地施加芯层的并最好覆盖地板整个前面的所有层。“装饰表面层”表示主要为地板提供装饰外观的层。“耐磨层”涉及主要用于提高前面的使用寿命/耐久性的层。在层压地板中，该耐磨层常常由含有三聚氰胺和氧化铝的透明纸构成。“加强层”表示主要用于提高表面层抗冲击和压力能力的层，有些情况下，可补偿芯层的不规则性，以使得在表面上看不到这些不规则性。在高压叠层中，该加强层通常由浸渍有酚树脂的棕色牛皮纸构成。“装饰层”表示以类似方式即在装饰表面层下面施加在加强层上的层，但是目的是获得预定外观，而不是获得加强效果。装饰层可以染成或以其一些它方式改变成与加强层相同，从而获得要求的外观。
“芯层最接近表面层的部分”通常表示芯层位于垂直锁定装置以上的部分，最好其离芯层表面层的距离比离垂直锁定装置的距离短。
根据以上定义，“胶合板”由几层木料交叉连接层构成，胶合板的内层看作是构成芯层，而外层看作是构成表面层、加强层和/或装饰层。
“水平面”表示平行于表面层外部的面。在连接位置，两并置的上接头边缘限定一“垂直接头(平)面。”
在前面和背面之间地板边缘的地板外部称为“接头边缘”。通常，接头边缘具有几个“接头表面”，它们可呈垂直、水平、有角度的、圆形、斜面等。这些接头表面可以由不同材料制成，例如层压板、纤维板、木材、塑料、金属(如铝)或密封材料。“接头边缘部”表示地板的接头边缘和地板部最靠近接头边缘的部分。“装饰接头部”通常表示地板表面仿造如石材或木材的可见接头的部分。
“接头”或“接头系统”表示共同配合的连接装置，其沿垂直和/或水平方向连接地板，“垂直”表示垂直于水平面的方向。“水平”表示垂直于相应接头的垂直接头面的方向。
上述技术可以用于制造可非常自然地仿造木制地板的层压地板。近年来，伪造石材、瓷砖和类似物变得越来越普遍。在本申请中，试图制造石材/板和瓷砖之间的尽可能自然的装饰接头部。其应该具有不同于这些石材的装饰和结构，还应该稍微低于水平面以仿造两石板或瓷砖之间的嵌入式接头。用于制造这些装饰接头部的技术成本高，而且不能获得自然的外观。如果以更简单和更低成本制造装饰边缘部并具有更自然外观，则应该可以扩大这种地板的销路。
现有技术及其问题：
当制造具有装饰和嵌入式接头部的层压地板时，原始材料是具有印刷接头边缘部的装饰纸。该纸通常浸渍有三聚氰胺树脂。在该操作中发生失控的膨胀。在随后的层压中，将该装饰浸渍纸放置在芯层上。最好将透明的耐磨层放置在该装饰纸上，接着靠着压花金属板进行层压，其中形成接头部，其通常具有不同于金属板其余部分的结构，并且将接头部设计成具有由层压形成的0.2mm的凹陷。从而获得一地板构件，其前面具有对应于例如瓷砖或石板之间预定接头部的嵌入式接头图案。
这种制造方法带来多种问题，首先是装饰纸和金属板关于层压的定位困难，以及随后锯切和加工接头边缘中地板构件和预制地板定位困难。
金属板必需相对于装饰纸进行高精度的定位。即使实现了高精度的定位，也不可能消除与浸渍有关的失控膨胀。该膨胀还带来接头边缘的锯切操作和加工中的问题。这些膨胀和定位问题的结果是，装饰和压花彼此不适合，不同地板之间的装饰嵌入式接头部发生变化，这导致外观看起来不自然。
为了克服这些问题，使用了不同方法。一种方法是限制地板构件的形式格式，以便由此减小有关膨胀的最大偏差。在装饰纸上制成可以在压制和锯切中可光学读取的特殊标记。接着使板尽可能精确地对准，可为每个地板构件进行锯片的单独调整。
这种方法的主要缺点是成本高、生产量低，成品地板中的装饰、压花和接头边缘之间留有很大的偏差。
而且，在高压叠层中难于形成不损坏装饰纸的深凹陷。直接层压的接头部凹陷导致芯层纤维被压缩。如果被压缩的纤维日后受潮了，则其膨胀会超过正常水平，导致接头边缘损坏。
已知层压地板或木制地板可具有呈圆形或以35-45度倾斜的上接头边缘。这种边缘加工主要是减轻两接头边缘之间的不同垂直位置的问题，不适于提供本发明能够提供的边缘设计。
发明内容
本发明的目的是消除或减轻具有装饰嵌入式接头部的地板在加工和使用中发生的一个或多个问题。本发明的另一目的是提供加工地板构件、预制地板和地板的合理而低成本的加工方法。
通过以下限定的地板系统和地板块全部或部分实现上述目的。
一种地板系统，该地板系统包括一对层压地板块，每个所述地板块具有一芯层、布置在该芯层上侧的装饰表面层、以及布置在地板块的相对边缘处的一对连接装置，所述连接装置用于使两个地板块沿水平方向彼此连接，其中当两个地板块连接时，在所述地板块的两邻接接头边缘之间获得装饰连接部，该表面层上最靠近所述邻接接头边缘的部分形成水平面，其特征在于，该装饰表面层是直接布置在该芯层上侧和直接层压在其上的浸渍有三聚氰胺的装饰纸，以便芯层的最靠近装饰纸的上部部分浸渍有三聚氰胺；并且，对于每个地板块，仅所述成对边缘中的一个边缘具有由芯层的最靠近表面层的浸渍有三聚氰胺的上部部分组成的表面，所述表面与水平面成大约0-10度，并且形成为可见的以便构成在地板块连接时的装饰连接部。
一种用于形成上述地板系统的层压地板块，所述地板块具有：芯层、布置在该芯层上侧的装饰表面层、以及布置在地板块的相对边缘处的一对连接装置，所述连接装置用于使地板块与相邻的相同地板块沿水平方向连接，其中当两个地板块连接时，在所述地板块的两邻接接头边缘之间获得装饰连接部，该表面层上最靠近所述相对边缘的部分形成水平面，其特征在于，该装饰表面层是直接布置在该芯层上侧和直接层压在其上的浸渍有三聚氰胺的装饰纸，以便芯层的最靠近装饰纸的上部部分浸渍有三聚氰胺；并且，仅所述成对边缘中的一个边缘具有由芯层的最靠近表面层的浸渍有三聚氰胺的上部部分组成的表面，所述表面与水平面成大约0-10度，并且形成可见的以便构成在地板块连接到所述相邻的相同地板块时的装饰连接部。
从以下优选方案以及说明书和附图中可明显得出本发明的实施例。
优选地，用于芯部的浸渍部分的浸渍材料被染色。
优选地，，所述连接地板块的接头边缘相接于一垂直接头面，所述芯层的表面由该接头面向内朝着相关地板块延伸一至少是地板块厚度的0.1倍的总体距离。
优选地，所述芯层具有由芯层上侧垂直向下延伸的表面部分，所述表面部分受浸渍以便改变至少该表面部分的外观。
优选地，所述表面部分受浸渍的深度至少为该地板块厚度的0.1倍。
优选地，所述地板块是四边形，并具有一层压表面层，所有接头边缘都受浸渍。
优选地，所述连接装置形成为用于所述地板块在与其垂直并垂直于所述表面层的一垂直接头面处的机械连接。
优选地，所述连接装置形成为用于通过向内形成角度和/或咬接到锁定位置而连接所述地板块中的一个和所述地板块中的预先安装的一个。
优选地，由所述芯层构成的所述表面的位置离地板表面层的距离比离所述连接装置的距离短。
本发明基于的是要在预制地板接头边缘的加工中加工装饰接头部的技术。接着进行层压和锯切，而对于对准没有任何特殊要求，不会带来膨胀问题。
可以通过将部分表面层最好是装饰表面层去掉而达到到露出下层的程度来提供装饰和嵌入接头部，并具有要求的装饰效果。该下层可以是例如作为加强层、装饰层或地板芯层的暴露部分的表面层。根据一实施例，加工到去除装饰表面层并保证下层露出的深度。根据一实施例，可以将下层的加工限制成必需达到要求的效果。因此，加工可以进行到这样的深度，使得在接头边缘的表面层被完全去除，但是不完全去除下层。在有些情况下，为了完全去除表面层，这会导致材料去除的程度达到是下层的材料被稍微去除掉。
还可以通过去除所有表面层而使芯层露出的加工，来提供装饰接头部。而且在这种情况下，可将加工深度限制到芯层最靠近表面层的部分。
根据一实施例，加工深度相对于地板厚度来说是很小的。这样的浅槽具有多种优点，例如，可提供不堆积灰尘而且易于清理的装饰槽。其它优点是，在表面层或最靠近表面层的芯层部分的加工中，不会导致地板使用寿命缩短、冲击强度或耐潮性降低。
已经发现，采用合适的加工设备和金刚石切割刀具，可以以0.01mm的精度部分去除表面层。因此可部分地去除表面层并使下层露出。该下层可以具有偏离/不同于地板其余表面的外观和结构并因此可构成嵌入式装饰接头部。
本发明特别适用于地板的接头边缘部中，但是还可在地板接头边缘部之间的任意位置布置一个或多个本发明装饰嵌入槽。
因此，地板可具有由多个表面部构成的表面，这些表面部之间带有装饰嵌入槽，由此形成有多个瓷砖或长块或类似物的表面图案。可以在地板表面上任意放置装饰部，它可以具有任意的范围或形状。装饰接头部可以位于两个已连接地板的两邻接边缘上。装饰接头部还可仅位于一个边缘上。接头部的范围可以但不需要覆盖整个接头边缘。装饰接头部可以与接头边缘平行，但是其还可以呈异形，如波形、齿形、楔形和类似形状。可以通过采用摆动刀具的加工或通过采用带压花表面的有斜度刀具的加工，来获得这些形状。沿其整个范围或在两邻接的接头边缘之间，装饰接头部距地板面的深度不需要相同。
本发明还特别适用于具有机械接头系统的地板，其允许地板彼此之间进行精确定位，并且在装饰接头部中没有暴露的接头间隙。这种锁定系统使装饰接头部具有自然的外观。
根据本发明第一方面，提供一种用于制造地板两邻接接头边缘之间的装饰接头部的系统，地板(各自)具有芯层和布置在芯层上侧的表面层以及设置在所述邻接接头边缘用于使地板沿垂直和/或水平方向彼此连接的连接装置，表面层上最靠近所述邻接接头边缘的部分形成水平面，表面层包括上层和下层。该系统的特征在于至少所述邻接接头边缘之一具有由下层构成的并基本平行于水平面的表面。
根据本发明这一方面，可以以多种不同方式加工装饰性可见/暴露加强层。构成加强层的牛皮纸在以后构成装饰接头部的部分中可以被整个或部分染色。可以过量进行部分染色，从而不导致其余生产过程中的定位问题。浸渍中使用的酚树脂或三聚氰胺可以被用于染色。可以在具有高压叠层和直接叠层(direct laminate)表面层的地板制造中布置装饰加强层。可以以相同方式加工塑料表面层或几层装饰单板层，以便提供装饰接头部。
最好距表面层上面的加工深度为表面层厚度的0.1倍，假如这足以露出下层。
距接头面向内的加工宽度根据所要形成的具有要求宽度的槽来定。当选定槽的宽度时，还要考虑是否仅邻接地板之一或二者都要设有装饰槽，每块地板的槽具有适当的宽度。
例如，距垂直接头面向内的加工宽度也可至少为地板厚度的0.1倍。这种装饰接头部适于仿造均匀/质镶木地板块或木制地板之间的接头间隙。距垂直接头面的暴露加强层的宽度可为地板厚度0.25倍。这种装饰接头部适于仿造两石板之间的接头。装饰接头部还可具有选自地板厚度的0.1-1.0倍之间的水平宽度。在厚度为6-9mm的常规层压地板中，这种装饰接头部的适宜水平宽度为0.5-3.0mm。
根据本发明的第二方面，可以去除芯层上的表面层以使得露出芯层。通过具有适宜特性的芯层，或者通过层压前或加工后的部分芯层或整个芯层芯层，其以方便的方式加工以便提供装饰外观或更好的防潮、耐磨损特性，由此采用芯层形成装饰嵌入接头部。
已经发现，机械接头系统通常要求使用合格的芯层材料来提供具有足够强度并且功能良好的机械接头系统。但是，这种高质量芯层材料不用于装饰目的，因为其由表面层隐藏。
根据本发明第二方面，通过去除表面层并露出待构成装饰接头部的芯层区域，来形成装饰接头部。
在本申请中，HDF和塑料材料特别方便。例如，HDF板即使在制造中也能采用不同着色剂对其染色，在层压前或后可以采用化学制品如三聚氰胺、酚、聚氨酯和类似物通过浸渍对芯层部分进行加强。露出的芯层可以例如在加工后受浸渍。该浸渍可采用化学制品如各种油或蜡很精确地进行。这些制剂能够渗透到芯层，并被吸入该层压面的下面。通过合适的机加工，可以非常精确地加工露出的芯层表面。当加工会造成一稍微大于表面层的深度时这是有利的。优点是，这种装饰接头部不聚集灰尘。如果表面层被直接层压，则这种机加工还会使露出芯层的表面具有良好的(防)潮湿和(耐)磨损特性。已经发现，当三聚氰胺浸渍纸压靠芯层时，处于表面层紧下面的芯层部分通过层压过程而浸渍有三聚氰胺。三聚氰胺渗透到表面层下面的芯层内大约0.2-0.4mm并粘结木纤维。三聚氰胺的渗透深度和量依赖于层压过程。基本与表面层平行并进行到表面层以下0.1mm的机加工是很有益的，因为露出的芯层表面接着包含大量的三聚氰胺。装饰接头部的质量特性因此受使用的合适层压方法的正面影响。使其更容易受三聚氰胺的影响的装饰层中更大量的三聚氰和较长压制周期和/或芯层表面的机加工可用于影响接头部的质量特性。当高压叠层或木材的表面层粘结在芯层上时，这也是适用的。胶渗透到芯层的上部并粘结纤维。地板构件和预制地板的生产过程中使用的胶、三聚氰胺和其它化学制品还可以着色，以用于获得装饰效果。可以将可见的接头边缘加工成多种不同形状，如圆形、不同角度的斜面和类似形状。可以在层压前后在芯层中制成槽，在其中填充有合适的填充材料，这些填充材料具有比芯层更耐潮湿和更适于装饰的特性。这些填充材料可放置在芯层中的一些区域中，当去除表面层或当接头边缘加工成其最终形状时，这些区域构成了可见部分。
地板表面可以设有任意装饰槽。在接头边缘和/或在接头边缘之间可形成一条或多条平行槽。这些槽还可是矩形、正方形、圆形、椭圆形或类似形状。有了现代化的生产方法，可以在地板表面形成高级图案。这种技术特别是适用于层压地板，但是还可用于其它种类的地板。
本发明的其它方面包括具有根据上述方面的系统的地板块、用于制造这种地板块的作为半成品的预制地板和制造这种地板块的方法。
下面参照附图详细描述本发明的实施例。
附图说明
图1a-d表示地板(块)制造的不同步骤；
图2a-e表示具有高压叠层和直接叠层表面的层压地板的合成；
图3a-b表示根据现有技术装饰性接头部的不同制造方法实例；
图4a-b表示本发明装饰性接头部；
图5a-c表示本发明装饰性接头部的另一实施例；
图6a-c表示本发明的不同实施例；
图7a-c表示本发明的地板块；
图8表示制造装饰性槽的制造方法；
图9a-d表示本发明的不同实施例；
图10a-e表示根据本发明制造的地板块的不同实施例；
图11a-b表示装饰性接头部的制造。
具体实施方式
图1a-d示出了地板制造的四个步骤。图1a表示三个基本组成部分表面层31、芯层30和平衡层32。图1b表示地板构件3，其中表面层和平衡层已安置在芯层上。图1c表示通过分割地板构件而制成预制地板2。图1d表示在机加工预制地板2的边缘后预制地板2形成其最终形状并成为具有连接系统7、7’的完整地板块1，在这种情况下是在长边4a、4 b上的机械式连接系统。
图2a表示高压叠层的制造。具有很高磨损强度的透明材料耐磨层34浸渍有添加氧化铝的三聚氰胺。浸渍有三聚氰胺的纸装饰层35置于耐磨层34下面。浸渍有酚的一层或多层芯纸加强层36a、36b置于装饰层35下面，将该整个叠层放置在压机中，使其在加热加压下固化成大约0.5-0.8mm厚的高压叠层的表面层31。图2c表示该表面层31接着与平衡层32一起粘结到芯层30上而构成地板构件3。
当制造紧凑叠层(compact laminate)时，整个芯层由加强层构成。
图2d和2e表示直接层压。浸渍有三聚氰胺的贴面板式耐磨层34和装饰纸装饰层35直接放置在芯层30上，之后这三部分通常还有背面的平衡层32被放置在压机中，使其在加热加压下固化成具有大约0.2mm厚装饰表面层31的地板构件3。最靠近装饰纸35的芯层上部在层压过程中将浸渍有三聚氰胺。通常，最靠近表面层的0.2mm的芯层浸渍有三聚氰胺。该部分的性能优于芯层的其它部分，不易受潮、更抗冲击和更耐磨。因此如果在芯层的该部分形成装饰接头部则很有益。用于连接表面层和芯层的粘结层可具有相同的作用。
图3a-b表示了根据现有技术的装饰接头部20、21的制造。图3a示出了锯切前的地板构件3。由于装饰纸的膨胀不受控制，因此表面压花达不到足够的精度。图3b示出了锯切和机加工后的地板边缘。装饰和压花明显偏离了预计位置。
图4a-b表示本发明装饰接头部20、21的制造。图4a示出了层压后但是还未锯切时的预制地板。通过机加工接头部制成了装饰接头部20、21。去掉装饰部表面层35而使得加强层36a露出并构成了装饰接头部20、21。本实施例中的地板边缘设有机械锁定系统，其由垂直锁定的槽9和榫舌10和水平锁定的锁定槽12和锁定件8构成。接头边缘可具有任意连接系统。本实施例中的装饰接头部20、21具有基本上相同的宽度和深度。两接头部20、21之间的宽度和深度还可以不同。
图5a-c详细表示了制造装饰接头边缘部的不同步骤，在本实施例中，其由基于木纤维的芯层30构成，该木纤维芯层30在层压前受浸渍和/或被染色。根据图5a，用喷嘴40向芯层表面33上的一部分施加染色的浸渍材料24，在制成的地板中该部分将构成装饰接头部20、21。预定的接头边缘上部的相当部分受浸渍，使得形成染色的并优选的防潮的芯层部。可采用真空46而便于浸渍材料渗透。
图5b示出了具有表面层31、平衡层32和预锯切口45的地板构件3。
图5c示出了锯切和机加工后的预制地板1、1’的边缘。
已经部分去除了表面层35，使得染色并暴露的芯层可见而构成装饰接头部20、21。作为层压前浸渍的可选择方式，图5c中的接头边缘部可以浸渍有例如在机加工后施加的不同疏水物质。这种物质可以是石油蜡、矿物油和类似物，其中可选地以任意方式加有颜料。可在几个步骤中通过提供便于渗透和硬化的能量进行施加这些物质。
图6a-c表示本发明的实施例。
根据图6a可以将装饰接头部机加工到距水平面HP的深度P2，该深度P2至少是表面层31厚度的0.1倍。根据图6a和6b，两地板1、1’接头部中从垂直面VP朝向地板内部的机加工宽度P1的总和优选地也大约是地板厚度T的0.1倍或更大。这样的装饰接头部适于仿造例如两木块之间的接头间隙。根据图6a的暴露加强层36a或根据图6b两接头边缘中的暴露芯层表面还可以具有相应于地板厚度T的约0.25倍的距垂直面的宽度。这样的装饰部适于仿造两石板之间的接头。可以有多种可选择方式。
两邻接地板1、1’之间的接头边缘可例如具有一个或多个装饰接头部，其暴露宽度一共为0.2至10mm。在图6a中，两邻接边缘在接头部中形成装饰槽，该装饰槽具有底面20、21和侧面22、23。侧面22、23与水平面HP的夹角为A1、A1’，该角度A1、A1’大于底面20、21的角度A2、A2’、A3、A3’。侧面的角度的变化范围最好为20-120度，底面的角度的变化范围最好为0-30度。侧面和底面的角度可以但不需要具有相同角度。本实施例的特别特征在于侧面22、23的角度大于底面20、21的角度。如果侧面的角度范围是40-60度，则这是很有益的。这降低了工具的磨损。如果底面20、21基本上平行于水平面，则也是很有益的。基本上平行意味着与水平面的夹角大约是0-10度。如果底面20、21是平面和由表面向下倾斜角度A3、A3’，则也是很有益的。
图6c示出了通过在层压之前或之后在芯层中制成槽而形成斜加强接头部80、81，然后在这些槽中填充装饰填充材料80、81，接着对装饰填充材料80、81机加工而使其形成装饰防潮部。
通过选择颜色对应表面装饰的填充材料，可以形成外观仿造例如具有斜接头边缘部的均匀木质地板的斜接头边缘。在接头边缘之间还可以制成类似的槽。作为可供选择的填充材料，可以使用木材、基于木质的板、塑料、压紧叠层和类似材料。这些材料可以连接在槽中。
图7a-c表示如何制造本发明具有底面20a、20b的槽并使其任意位于装饰接头部2 0之间的地板表面上。最好，用于仿造地板接头边缘处的装饰接头部20的该槽20a、20b应具有的宽度是接头部20宽度的两倍，使得所有装饰接头部和槽一旦地板被连接便具有相同外观。
图8表示如何制造图7所示的装饰连接部。通过使地板穿过固定在链条50、51和皮带60、61之间的铣床，通常首先穿过加工长边的第一铣床并接着穿过加工短边的第二铣床，来加工地板的外接头边缘部20。根据现有技术，具有相应铣削电动机70、72的刀具位于链条外侧并加工这些接头边缘。通常，每侧使用多达5个刀具，这些刀具位于不同角度以加工这些接头边缘。为合理地制造具有位于接头边缘之间的装饰槽的本发明地板，必须能加工链条50、51之间的地板表面。根据本发明，通过设有长刀具轴的一个或多个铣削电动机进行加工是最方便的，使得该铣削电动机可以位于链条的外侧，同时由刀具71完成链条之间的机加工。这在要制造靠近接头边缘的装饰槽时是特别有益的。在链条50、51之间还可以设置单独的铣削电动机。为了合理加工在接头边缘处和/或接头边缘之间设有机械锁定系统和装饰接头部的地板，通常有必要将每边上的机加工电动机和刀具的数量提高至6个。如果刀具的数量提高到每边为6至8个则可使加工更为合理。对接头边缘之间地板表面中的槽进行加工的刀具71应该垂直即垂直于地板表面操作。机加工接头边缘的刀具能够垂直、水平或以不同角度操作。
根据这些优选方法的地板特别是层压地板的加工不是公知的，目前没有出现。更不要说能够在单独操作中加工这些装饰槽了，但是这种加工比起在同一设备的一次操作中加工所有平行装饰槽的情况来说，成本更高，而且变化相当大。用根据图8的优选加工方法加工出的槽深度和侧面中的精度可达到百分之几毫米的公差。
图9a-d表示如何仅在两连接地板1、1’的一个边缘上形成装饰槽133。本实施例具有几个优点。刀具的数量可以减少，接头间隙更不明显。在图9a中，侧面22和23垂直于水平面HP，而底面21平行于表面。在图9b中，对侧面22和23底切并根据线11a、11b形成角度。有角度的侧面22可隐藏地板上接头边缘之间的间隙。图9c表示带有角度的底面21和侧面23的实例。图9d仅表示一水平接头系统。装饰槽133具有成角度的侧面22和倒圆的侧面23。根据图9a-9d的接头边缘的所有优选实施例可以进行组合。显然在本发明范围内可以使用其它角度、半径、深度和宽度。
图10a示出在一条长边133a和一条短边133b上有装饰槽的地板。图10b示出仅在一条长边133a上有装饰槽的地板。图10c和10d表示由根据上述图中的地板构成的地面。图10e示出了在长边和短边上的两平行槽135、133a和134、133b。在本实施例中，这些槽具有不同宽度。本实施例中，地板的表面中还具有椭圆形槽136。
显然，所有优选实施例可以彼此自由组合，而且可以任意设计这些槽的数量、宽度、深度、三维形状等。可以将地板设计成使其以长边对长边、短边对短边或长边对短边的形式连接。接头系统和/或装饰槽可以呈镜像式颠倒，并可以人字形图案铺设，使得地板不必具有平行的相对侧。
图11a表示如何通过金刚石刀具TP1在例如层压地板中形成装饰接头部，本实施例中的金刚石刀具TP1以与水平面HP成大约4 5度的角度TA进行工作。叠层的耐磨层中的氧化铝导致点WP的磨损很严重。如果刀具的形状呈台阶状则能减轻该问题。当金刚石的部分被磨损时，刀具能够移动到图11b中的位置TP1’。刀具还能够沿垂直方向以百分之几毫米的幅度移动。槽的深度会改变，但是视觉上难以分辨十分之几毫米的差别，特别是在两邻接边缘中仅一个边缘上设有装饰接头部的情况下更是如此。刀具TP1可以以其它角度工作。在本实施例中，表面层的厚度大约为0.2mm，槽的宽度P1约为1mm，槽的深度P2约为0.3mm，三聚氰胺在表面层下面的渗透深度2 5的范围为0.2至0.4mm。这种装饰接头部是适用于呈拼花/镶木地板块形式并铺设成平行排列、菱形图案或人字形图案的地板中。在这些情况下，装饰接头边缘便于仅布置在每块地板的一条长边和一条短边上。通常，芯层浸渍有比地板表面颜色更深的彩色颜料。

Claims (10)

1.一种地板系统，该地板系统包括一对层压地板块(1、1’)，每个所述地板块(1、1’)具有一芯层(30)、布置在该芯层上侧的装饰表面层(31、35)、以及布置在地板块的相对边缘(4a、4b、5a、5b)处的一对连接装置(9、10、8、12)，所述连接装置用于使两个地板块沿水平方向彼此连接，其中当两个地板块连接时，在所述地板块(1、1’)的两邻接接头边缘之间获得装饰连接部(20、21)，该表面层上最靠近所述邻接接头边缘的部分形成水平面(HP)，其特征在于，该装饰表面层是直接布置在该芯层(30)上侧和直接层压在其上的浸渍有三聚氰胺的装饰纸(35)，以便芯层(30)的最靠近装饰纸(35)的上部部分浸渍有三聚氰胺；并且，对于每个地板块，仅所述成对边缘中的一个边缘(4a、4b、5a、5b)具有由芯层(30)的最靠近表面层的浸渍有三聚氰胺的上部部分组成的表面，所述表面与水平面(HP)成大约0-10度，并且形成为可见的以便构成在地板块连接时的装饰连接部。
2.如权利要求1所述的地板系统，其特征在于，用于芯部(30)的浸渍部分的浸渍材料被染色。
3.如权利要求1或2所述的地板系统，其特征在于，所述连接地板块的接头边缘相接于一垂直接头面(VP)，所述芯层的表面由该接头面(VP)向内朝着相关地板块(1、1’)延伸一至少是地板块厚度的0.1倍的总体距离(P1)。
4.如权利要求1所述的地板系统，其特征在于，所述芯层具有由芯层上侧垂直向下延伸的表面部分，所述表面部分受浸渍以便改变至少该表面部分的外观。
5.如权利要求4所述的地板系统，其特征在于，所述表面部分受浸渍的深度至少为该地板块厚度的0.1倍。
6.如权利要求4或5所述的地板系统，其特征在于，所述地板块(1、1’)是四边形，并具有一层压表面层(31)，所有接头边缘都受浸渍。
7.如权利要求1所述的地板系统，其特征在于，所述连接装置(9、10、8、12)形成为用于所述地板块(1、1’)在与其垂直并垂直于所述表面层的一垂直接头面(VP)处的机械连接。
8.如权利要求1所述的地板系统，其特征在于，所述连接装置(9、10、8、12)形成为用于通过向内形成角度和/或咬接到锁定位置而连接所述地板块中的一个(1)和所述地板块中的预先安装的一个(1’)。
9.如权利要求1所述的地板系统，其特征在于，由所述芯层(30)构成的所述表面的位置离地板表面层的距离比离所述连接装置的距离短。
10.一种用于形成权利要求1的地板系统的层压地板块，所述地板块(1、1’)具有：芯层(30)、布置在该芯层上侧的装饰表面层(31、35)、以及布置在地板块的相对边缘(4a、4b、5a、5b)处的一对连接装置(9、10、8、12)，所述连接装置用于使地板块与相邻的相同地板块沿水平方向连接，其中当两个地板块连接时，在所述地板块的两邻接接头边缘之间获得装饰连接部(20、21)，该表面层上最靠近所述相对边缘的部分形成水平面(HP)，其特征在于，该装饰表面层是直接布置在该芯层(30)上侧和直接层压在其上的浸渍有三聚氰胺的装饰纸(35)，以便芯层(30)的最靠近装饰纸(35)的上部部分浸渍有三聚氰胺；并且，仅所述成对边缘中的一个边缘(4a、4b、5a、5b)具有由芯层(30)的最靠近表面层的浸渍有三聚氰胺的上部部分组成的表面，所述表面与水平面(HP)成大约0-10度，并且形成可见的以便构成在地板块连接到所述相邻的相同地板块时的装饰连接部。
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