CN102458802A - 用于制造贴面薄片的方法 - Google Patents

用于制造贴面薄片的方法 Download PDF

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Publication number
CN102458802A
CN102458802A CN2010800324871A CN201080032487A CN102458802A CN 102458802 A CN102458802 A CN 102458802A CN 2010800324871 A CN2010800324871 A CN 2010800324871A CN 201080032487 A CN201080032487 A CN 201080032487A CN 102458802 A CN102458802 A CN 102458802A
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China
Prior art keywords
described method
thin slice
layer
granular materials
formed body
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Granted
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CN2010800324871A
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English (en)
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CN102458802B (zh
Inventor
霍尔格·马罗恩
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Individual
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Individual
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Abstract

本发明涉及一种用于制造贴面薄片(1)的方法，包括以下步骤：将稳定剂与颗粒材料(2)混合；将颗粒材料(2)填充在容纳构件(3)中，该容纳构件形成为成型体(4)；使成型体的至少一个表面层(9)与载体层(10)连接；取下由表面层(9)和载体层(10)构成的复合结构，由此获得贴面薄片(1)。本发明还涉及一种用本发明方法制成的贴面薄片(1)以及该贴面薄片用于覆盖在盖子、墙壁、地板、门、顶棚和/或桌面上的用途。

Description

用于制造贴面薄片的方法
技术领域
本发明涉及一种用于制造贴面薄片(Sichtbelag)的方法、一种用本发明方法制造的贴面薄片以及该贴面薄片用于覆盖在盖子、墙壁、地板、门、顶棚和/或桌面上的用途。
背景技术
开始所述类型的贴面薄膜基本上是公知的，并且通常，这种贴面薄膜作为装饰表面用在地板、盖子、家具和类似物上。
贴面薄片可以由不同的材料构成，例如天然石料、诸如板岩、大理石、花岗岩或陶瓷材料。这些材料的优势在于具有装饰性的外观以及耐磨性能。
然而缺陷在于，这些材料大多很脆、很重而且不具有挠性，因此使这些材料对于不同需求的应用受到限制。此外，这些材料在基质上的固定通常成本很高，并且仅在采用重的建筑材料、诸如砂浆、水泥或类似材料的情况下才能实现。这些材料的其它缺陷还在于，对于这些材料固定于其上的基质来说，相应地在稳定性和抗弯强度方面的要求很高。例如，难以实现将天然石料覆盖在木结构上，这是因为由于温度和/或湿度的波动会使这种结构产生膨胀、收缩或弯曲，由此随着时间推移会导致损坏，诸如在材料中出现裂缝。
公知地，天然石料复合板，例如砂石复合板，在砂槽中通过平整砂壁、对砂壁进行背面加固、然后涂覆分散粘合剂而制成。在分散粘合剂干燥亦或是聚合之后，取出所生成的复合板。在复合板的可视面上对该砂壁的颜色和表面形状进行造型处理。
上述方法的主要缺陷在于，严格受限于天气情况。在寒冷的天气情况下而且用可拆卸表面盖屋顶的条件下，这样的复合板会产生质量损失。另外，在这种情况下还需要较长的干燥和硬化时间。
另一种不利的天气影响是下雨。在下雨时，地板吸收水，这样在可拆卸表面上会导致湿气的加重直至造成雾状的排水现象。这样又会导致在复合板中出现严重缺陷，直至复合板的完全不能使用。
此外，缺陷还在于可拆卸表面的不同的强度。这一点根据地质学的情况会产生剧烈变化，因此需要实现粘接材料和粘合剂之间的稳定匹配。
最后，以前述方法即使在采用强粘接剂或粘合剂的情况下，仍然不能实现对硬质的天然石料类型、诸如花岗岩和大理石的拆卸。
已经尝试这样解决前述问题，即，对由石料构成的薄片进行剪切，并且将其粘接在载体上，载体例如为金属基质。然而，这种技术方案的缺陷在于，难以实现薄层的切割，并由此而耗费时间。此外，所获得的层状制品通常很脆且易断裂，所以在其应用性上受到限制。
由WO 2008/022812公开了一种挠性的平面材料，该表面材料包括表面层和挠性抗拉的载体层，表面层具有由多层石料制成的层状结构，载体层承载表面层；并且，该表面材料还包括粘接层，用于将平面材料固定在基质上。
由WO 01/75246公开了一种用于制造固定砂层方法，其中，分层面结构由砂层和支撑层构成。在该方法中，支撑层铺设在平整的砂面上，支撑层与固定上方砂层的粘合剂或粘接剂形成接触，然后分别取出各个制成的分层面结构。
为了在将分层面结构取出之前确保砂层的成型结构，建议使砂料的填充用侧壁包围住。
上述方法的缺陷是，利用侧壁对砂料的填充进行包围对于可靠地确保砂料的成型结构具有局限性。由于砂料具有孔隙，所以砂料在震动过程中会扬散落下，这样会使原有的结构消失。
发明内容
本发明的目的在于避免现有技术中的缺陷。
上述目的通过一种用于制造贴面薄片的方法来实现，包括以下步骤：
a)将颗粒材料与稳定剂混合；
b)将颗粒材料填充在容纳构件中，该容纳构件形成为成型体；
c)使成型体的至少一个表面层与载体层连接；
d)取下由表面层和载体层构成的复合结构，由此获得贴面薄片。
相对于现有技术，本发明方法的特征在于，颗粒材料与稳定剂混合，然后与载体层连接。稳定剂的引入使颗粒材料的成型稳定性提高，由此即使在震动的情况下、例如存放或运送过程中也能够确保颗粒材料的成型结构。以这种方式可以对颗粒材料中的所需成型结构进行预先设置、存放，并且在需要的情况下转移到贴面薄片上。
此外，本发明方法的特征还在于，使颗粒材料以相对较少的量就能制成具有连续的装饰表面的贴面薄片。也就是说通过本发明的方法特别有效地利用所存在的资源。这方面的优势特别对于应用贵的和/或稀有材料时具有重要意义。
本发明方法的另一个优势在于，实现了在不依赖于天气影响的空气条件下对贴面薄片的批量制造。此外，通过本发明的方法还可以使贴面薄片以同样的质量进行生产，特别具有优势的是能够保证满足诸如对于建筑涂层的技术标准。
在本发明方法的第一步骤中，将颗粒材料与稳定剂混合。
作为颗粒材料，基本上可以采用不同的物质。特别这样实现外形优美的贴面薄片，即，通过采用天然石料、合成材料、木材和/或金属；天然石料优选采用砂石、石英、石英砂、花岗岩、板岩、大理石、玻璃、凝灰岩、次石墨(Shungit)、石英岩；合成材料优选采用丙烯酸酯、聚酰胺；金属优选采用耐腐蚀金属，特别是铜、青铜、黄铜、铝。
特别适宜地，作为颗粒材料采用颗粒物料，因为颗粒物料具有良好的震动性能并且便于操作。经实际试验表明，当采用的颗粒物料的D50值为0.01mm至5mm、优选0.02mm至1mm，和/或平均颗粒尺寸为0.05mm至5mm、优选0.1mm至1.5mm时，能够得到特别好的试验结果。
基本上，颗粒材料可以采用任意的筛分曲线构成(Sieblinienaufbau)。然而特别具有优势的是，使颗粒材料采用这样的筛分曲线构成，即，能够形成紧密的材料组织结构，而不会消耗较大的压缩能量。技术人员通过简单的试验就能够发现，什么样的筛分曲线构成适用于任意采用的颗粒材料。
经试验证实，在采用粉料、砂料、碎石和/或其混合物作为颗粒材料时特别实现了良好的试验结果。特别通过粉料、砂料、碎石和/或其混合物实现了良好的试验结果，这些材料的平均颗粒尺寸分别为：
粉料：20-100μm，
砂料：50-1000μm，
碎石：0.1-5.0mm、优选0.1-1.5mm。
为了改善本发明的贴面薄片的性能，还可以使颗粒材料含有辅助剂，诸如防火添加剂、疏水剂、气味吸附剂和/或有害物质吸附剂、和/或着色剂，有害物质吸附剂优选二氧化钛，着色剂优选色素。
特别优选，对于颗粒材料的使用过程中还混合有优选在制造过程中产生UV效应的TiO2化合物，例如以粉末或溶胶溶剂的形式进行混合。如果贴面薄片用作外壁装饰，那么上述添加剂会在阳光(UV)下使有机颗粒、诸如苔藓、藻类或芽孢等分解，即能够破坏或是冲掉这些有机颗粒。由此的结果是能够获得具有持久清洁表面的贴面薄片。
颗粒材料还可以含有加固材料。作为加固材料例如可以采用高强度纤维。高强度纤维是公知的，并且包括有机的和无机的强化纤维，诸如玻璃纤维、碳纤维、凯夫拉纤维、建筑纤维和类似纤维。纤维可以作为经切割的单独纤维而存在。在此其优势在于，使单独纤维的长度不超过颗粒材料的最大颗粒尺寸。还可以考虑，使纤维以织物或非织物材料的形式存在，以网垫的形式存在，以由基本上连续的细丝构成的层的形式存在，以由纤维构成的绞合线或绞索的形式存在。
根据本发明，使颗粒材料与稳定剂混合。本发明物质中的稳定剂可以理解为，适用于确保使颗粒材料至少临时保持其结构形式。作为稳定剂，基本上可以采用不同的物质。通过对稳定剂的选择可以对颗粒材料的结构确定的程度有针对性地进行调整。
技术人员通过简单的试验就能够发现，在各种采用的颗粒材料中什么样的稳定剂适用于实现所需的稳定性。对于通常的应用目的特别适用的稳定剂是砂砾和/或水。
选择稳定剂的主要标准是其稳定效果的程度。在有些情况下还可以适宜地采用稳定效果很弱的稳定剂。使用弱稳定剂的优势在于，使颗粒材料的成型结构保持可变性。通过使用弱稳定剂实现了，即使在混合稳定剂之后也能产生不希望的结构改变。
根据本发明，特别适宜的弱稳定剂为水、膨胀土、甲基纤维素、多糖、聚乙烯醇、酪蛋白、粘土、皂石、海泡石、瓷土、氧化锌和/或水玻璃。
在有些情况下，还有意义的是采用具有强稳定效果的稳定剂。根据本发明，特别适宜的强稳定剂为粘合剂和/或粘接材料，诸如可再分散的分散粉末、合成材料分散系、树脂乳液。如技术人员公知的那样，利用稳定剂所实现的效果强度还可以通过添加数量来控制。
颗粒材料的强稳定性的优势在于，能够特别可靠地实现预设结构的稳定性。此外，还确保实现了颗粒材料的表面结构，由此，在对贴面薄片的加工过程中不会产生贴面表面的断裂或损坏，例如由于“扬散落下(Rieseln)”造成的损坏。
在有些情况下，需要仅临时保持颗粒材料的结构。对于该目的，可以采用稳定效果可逆的稳定剂。根据本发明，可逆式稳定剂可以理解为稳定效果可以重新消除的稳定剂。
适宜的可逆式稳定剂例如为水、纤维素、糖类、聚乙烯醇、酪蛋白、膨胀土。
通过哪些方式使可逆式稳定剂的稳定效果能够消除取决于所采用的稳定剂的类型，并且，这对于技术人员是公知的。如果例如采用水作为可逆式稳定剂，那么其稳定效果以简单的方式通过干燥处理就能够重新消除。粘合剂、诸如纤维素、淀粉和/或糖化物的稳定效果可以通过添加溶剂、诸如水而消除。
采用可逆式稳定剂的优势在于，使弱稳定剂和强稳定剂的优势统一。通过采用可逆式稳定剂实现了，在颗粒材料中预设的成型结构即使在与稳定剂混合之后也可以改变。然而能够实现持久稳定的成型结构。此外，稳定剂的硬化——例如当用于取下贴面薄片的成型体的表面太硬、和/或表面涂层的厚度以不希望的方式不均匀时——可以逆向进行。
在有些情况下，却希望采用不可逆式稳定剂。采用不可逆式稳定剂的优势在于，可以获得结构模的持久稳定性。由此导致的结果是，所形成的贴面薄片还具有较高的结构强度，并且具有均匀厚度且封闭的表面层。适宜的不可逆式稳定剂例如为环氧化物乳液、聚氨酯乳液、诸如丙烯酸酯的热塑性分散体、丙酸、苯乙烯丁二烯和/或水玻璃。
特别适宜地，作为稳定剂采用粘接剂和/或粘合剂，它们的有效物质适用于内部和外部应用。
本发明的稳定剂的采用还实现了本发明的一个特别优选的实施方案。根据该实施方案，在成型体中形成至少一个凹陷部，凹陷部例如为裂缝或凹槽。在此采用稳定剂的优势在于，使所形成的凹陷部稳定，并由此能够避免凹陷部以不希望的方式被再次填充。根据本发明，然后使至少一部分该凹陷部用对比剂填充，其中，形成人工结构图案。
通过本发明的前述实施方案能够制成一种具有人工结构图案的、特别具有装饰性的贴面薄片。
凹陷部的结构可以通过不同方式来实现。特别良好的结果可以由此实现，即，使凹陷部通过成型体的空间位置变化而形成。这种变化例如通过对容纳构件的敲击和/或震动来实现。
根据本发明的另一特别优选的实施方案，成型体中的凹陷部通过容纳构件的底面的变形而形成，和/或通过设置在容纳构件的底面和成型体之间的薄膜的变形而形成。为了实现该目的，可以使容纳构件的底面和/或薄膜设计成至少局部可变形。以这种方式能够实现特别外形优美的结果。
底面和/或薄膜的变形能够以简单的方式实现。通过底面逐点的、优选在一侧的提升而实现良好的结果。
根据本发明的一个特别优选的实施方案，底面的变形、和/或设置在容纳构件的底面和成型体之间的薄膜的变形，通过冲压体在成型体底面和/或薄膜中的冲压而实现。在此，冲压体既可以具有形状稳定的结构，又可以具有可变形结构。为实现前述目的，特别适宜采用可变形坚实物体的冲压，优选在底面的背向成型体的一侧上进行冲压。
根据本发明，以前述方法形成的凹陷部填充有对比剂，其中，形成人工结构图案。该结构模为本发明的贴面薄片提供了一个特别自然的外观。
人工结构图案的外观主要由凹陷部的形状和数量来确定，并且特别可以以这样的方式和方法而受到影响，即，通过该方式方法使成型体的空间位置产生变化，也或是使成型体底面产生变形。技术人员通过简单的尝试就能发现，采用哪种方式能够获得所需的结构图案。
对于人工结构图案的外观的另一个主要因素在于对对比剂的选择。在本发明的材料范围内，对比剂可以理解为这样的材料，其能够在视觉和/或触觉方面与颗粒材料相区分。
基本上，作为对比剂可以采用与颗粒材料类似的材料，只要该对比剂能够在视觉和/或触觉方面与颗粒材料进行区分。这样的区分例如可以通过颜色、结构、组成成分、颗粒尺寸和/或筛分曲线构成来得出。在颗粒材料和对比剂之间的颜色对比能够得到特别外形优美的结果。在此，颜色对比既可以通过材料的不同组成成分来实现，又可以通过采用不同的着色剂、诸如颜料和色素来实现。
根据本发明，在实际应用中有利的是采用固体材料作为对比剂。
原理上还可以采用液体，只要使这些液体可以凝固。
为了改善贴面薄片的性能，对比剂还可以含有辅助剂，诸如防火添加剂、疏水剂、气味吸附剂和/或有害物质吸附剂、和/或着色剂，有害物质吸附剂优选二氧化钛，着色剂优选色素。
在本发明方法的步骤b)中，将颗粒材料填充在容纳构件中。根据本发明，优选在方法步骤a)之后进行方法步骤b)。该方案的优势在于，使颗粒材料和稳定剂的混合能够以特别简单的方式例如在操作常用的自动混合装置中进行。在该顺序中需要注意，尽管与稳定剂混合，但是仍然保证颗粒材料的可填充性。这样的可填充性例如可以通过采用仅进行弱稳定的稳定剂来确保实现，和/或通过采用时间上延迟起作用的稳定剂来确保实现。
在有些情况下，适宜在方法步骤b)之后进行方法步骤a)。在这种情况下，首先将颗粒材料填充在容纳构件中，然后使至少一部分颗粒材料与稳定剂混合。当采用强的和/或快速强化的稳定剂的条件下，这种方案特别具有优势。
如果方法步骤b)在方法步骤a)之前进行，那么适宜地，仅使一部分颗粒材料强化。在这种情况下，该强化部分的颗粒材料优选形成为表面层。在此，表面层的厚度和强度以简单的方式受到所采用的稳定剂的粘度的影响。粘度较大的粘合剂或粘接剂比粘度较小的粘合剂或粘接剂侵入的深度小。此外，强化的表面层的厚度和强度还可以根据对于稳定剂的类型和数量的选择而得到控制。
实际试验表明，可以由此获得特别装饰的贴面薄片，即，使成型体通过采用颗粒材料而形成，颗粒材料含有至少两种成分，这至少两种成分在视觉上、优选从颜色上相互区分。含有颜色可区分的成分的颗粒材料的应用实现了，在成型体中预先形成图案，该图案为贴面薄片提供了一个独一无二的具有装饰性的外观。通过该实施方案，既能够仿制出天然的条纹，又能够造出人工的图案。
如上文所述，具有优势的是容纳构件具有至少部分可变形的底面。底面的可变形性能例如可以通过采用挠性材料作为底面而实现。特别良好的结果可以这样实现，即，使底面由金属和/或合成材料构成，优选由聚氨酯、聚氯乙烯和/或硅树脂构成。这些材料例如能够以弹性网垫亦或是弹性面的形式来应用。
如果希望得到较稳定的底面，那么可以通过选择形状稳定的材料、和/或通过在底面引入填充料来实现。可替换或额外地，还可以使底面包括加固附件。
此外还具有优势地，使容纳构件除了包括底面之外还包括至少一个侧壁。适宜地，使底面和侧壁都在内侧主要形成光滑平面。以这种方式可以避免在贴面薄片构造中不希望的不均匀性。
实际试验表明，特别适宜地，在该容纳构件的侧壁和/或底面上设有薄膜，该薄膜作为分离层和/或滑动层特别由乳胶、聚异丁烯、聚乙烯、硅树脂、聚氨酯、尿素和/或以可回收网垫的形式构成。
如果侧壁设在容纳构件中，那么侧壁优选形成为封闭的框架。该框架可以具有不同的形式。经证实，特别适宜地，框架具有矩形和正方形结构。
框架的尺寸根据所需的贴面薄片的尺寸来确定。实际试验证明，当容纳构件的矩形或正方形底面的尺寸为1至5m、优选2至4m，乘以0.3至3m、优选0.6至2m，高度为0.05至0.8m、优选0.1至0.5m时，特别实现良好的结果。
此外具有优势地，在将颗粒材料装入时，容纳构件在填充方向上是敞开的，并且在填充过程之后、例如在运送和/或存放过程中、至少在容纳构件的底部和侧面区域中是封闭的。
根据本发明的另一优选的实施方案，这样构成容纳构件，即，可以在填充方向上抬起该容纳构件的底面。当填充料以分层的方式铲平时，该实施方案特别有利。
当颗粒材料以分层的方式铲平时，可以使成型结构中的新铲平的每一层都对应于之前的层。这样实现了，例如在壁纸应用中，使结构相互补充的平面板块按照顺序排列。
在本发明方法的步骤c)中，使成型体的至少一个表面层与载体层连接。
根据本发明，表面层可以理解为成型体的这样一层结构，该层结构包括成型体的背向容纳构件底面的表面。该表面层既可以包括一部分成型体，又可以包括整个成型体。
根据本发明，作为载体层可以采用不同材料。适宜地特别使用具有孔隙的载体层。在这种情况下，载体层与表面层的连接可以特别简单地通过粘合剂和/或粘接剂来实现。对此，首先可以将载体层涂覆在表面层上，然后将粘合剂和/或粘接剂涂覆在载体层的背向表面层的一侧上。在这种情况下，可以使粘合剂和/或粘接剂渗入载体层，并且形成表面层和载体层之间的复合结构。在此实现了特别良好的复合结构粘附作用。
还具有优势的是采用挠性载体层。在这种情况下获得挠性贴面薄片，该挠性贴面薄片能够顺利地贴附在基质的不平的表面、角和/或边上。
若作为载体层采用织物、无纺布和/或针织物时，可以获得优异的结果。如果需要高强度的载体层，那么可以使载体层额外含有加固材料，例如加固纤维。为了增大贴面薄片的硬度，还可以在载体层的背向表面层的一侧上涂覆加强层，该加强层例如为刨花板和/或中密度纤维(MDF)板。
表面层与载体层的连接可以以不同的方式和方法、优选通过采用粘合剂和/或粘接剂来实现。对于采用有孔隙的载体层特别有利的方式已经进行说明。
不同方式的适宜应用特别取决于对载体层材料的选择以及对用于稳定表面层的稳定剂的选择。
如果采用强稳定剂，那么在本发明方法的步骤a)中已经生成强化的表面层。该表面层可以以简单的方式例如经由粘合剂、诸如粘接材料与载体层形成连接。粘接材料的应用由于其方便的可操作性以及良好的配量性而特别适宜。
根据本发明，特别适宜的粘接材料为合成树脂。合成树脂可以是热塑性或热硬化性合成树脂。适宜用于制造合成树脂的聚合物包括饱和和不饱和的聚烯烃，诸如聚乙烯和聚丙烯、乙烯聚合物和乙烯共聚物，例如聚氯乙烯(PVC)、聚苯乙烯或类似材料；丙烯酸酯聚合物，例如丙烯酸和异丁烯酸的聚合物和共聚物以及它们的酰胺、酯、盐和对应的腈；聚酰胺；聚酯；环氧树脂；聚氨酯；前述这些以及其它热塑性和热硬化性的聚合物的混合物和共聚物，诸如丙烯腈/丁二烯/苯乙烯共聚物(ABS)；以及类似材料。
根据本发明特别适宜的聚酯聚合物为具有二羟基醇的乙二酸的缩聚产物。该产物可以由一定数量的输出试剂获得，该试剂含有以下材料：马来酸、富马酸、酞酸、异酞酸(Isophtal saeure)、对苯二酸(Terephtal saeure)、肥酸和其它酸和及其酸酐以及乙烯、丙烯、二乙烯、二丙烯、1，4-丁烯和己二醇和类似材料。
特别适宜的丙烯酸酯聚合物是甲基丙烯酸甲酯、丙烯酸乙酯和丙烯腈。聚合物可以分别以均聚物的形式使用、或与其它不同的单体一起使用，由此实现了共聚合。对于本发明有利的丙烯酸酯聚合物的额外的示例为聚丙烯酸酯和聚甲基丙烯酸酯，其中涉及到丙烯酸酯和甲基丙烯酸酯的均聚物或共聚物，诸如聚丙烯酸异丁酯、聚甲基丙烯酸甲酯、聚甲基丙烯酸乙基己酯、聚丙烯酸乙酯；不同的丙烯酸酯和/或甲基丙烯酸酯的共聚物，诸如甲基丙烯酸甲酯/丙烯酸环己酯共聚物；以及，丙烯酸酯和/或具有苯乙烯和/或α甲基苯乙烯的丙烯酸酯的共聚物，诸如，前聚物和共聚物，和聚合物混合物，聚合物混合物由丙烯酸酯、甲基丙烯酸酯、苯乙烯和丁二烯组成。
这样制成在本发明实际应用中将使用的聚氨酯聚合物，即，使聚异氰酸酯，诸如甲苯二异氰酸酯、二苯基甲烷二异氰酸酯和环己二异氰酸，与一种化合物发生反应，该化合物具有至少两个活性氢原子，诸如多元醇、多胺和/或聚异氰酸酯。提供了充分的对于实现本发明有用的聚氨酯树脂。
还可以采用不同的环氧树脂，该环氧树脂这样制成，即，使环氧基团(由氧原子与另外两个原子、通常与另外两个碳原子结合而成)、诸如表氯醇，或者氧化的聚烯烃、诸如环氧乙烷，与脂肪醇-或芳香醇、诸如双酚A、甘油等发生反应。
此外，还可以采用由乙烯聚合物构成的粘接剂，诸如根据现有技术公知的，例如为聚氯乙烯、聚醋酸乙烯、聚偏二氯乙烯、聚苯乙烯和这些材料的共聚物。
在本发明方法中，所提及的粘接剂或粘合剂还可以用作稳定剂。
实际试验证明，利用热塑性分散系、优选基于丙烯酸酯、苯乙烯丙烯酸酯、苯丙酮(Propiophan)、合成橡胶和/或热固塑料，优选MS聚合物、聚硫化物、环氧化物、聚氨酯和/或聚酯，可以实现特别好的结果。同样表现优异地还适合采用异氰酸酯预聚合物、聚甲基丙烯酸甲酯和/或它们的混合物。
根据应用条件有意义的是，在表面层和载体层的复合结构中形成的粘接层例如通过网格结构来加固。
如果作为稳定剂采用弱的和/或可逆式稳定剂，那么本发明的优势在于，表面层和载体层的复合结构通过粘合剂来实现。在这种情况下，粘合剂具有双重作用。第一，粘合剂贯穿成型体的表面层，并使表面层强化。第二，形成由表面层和载体层构成的复合结构。对于该目的特别适宜的粘合剂例如为热塑性分散系，该热塑性分散系基于丙烯酸酯、苯乙烯丙烯酸酯、Propiophan、合成橡胶和热固塑料，例如特别为MS聚合物、聚硫化物、环氧化物、聚氨酯、聚酯。
额外地，可以在加固层的背向表面层的一侧上涂覆一层粘接材料层，用以将贴面薄片固定在基质上。该粘接材料层优选设有保护层，该保护层根据需要能够便于取下。该粘接材料层可以铺设适宜的薄膜或类似的薄片而用作覆盖材料，从而使贴面薄片能够顺利地进行包装、存放和运送。在使用贴面薄片之前，可以先将薄膜或薄片取下，然后将贴面薄片以简单的方式粘贴在基质上。以这种方式可以使贴面薄片的安装快速、简单且成本低廉。
在本发明方法的步骤d)中，取下由表面层和载体层构成的复合结构，由此获得贴面薄片。
实际试验证明，特别优良的贴面薄片可以这样获得，即，在取下由表面层和载体层构成的复合结构之前和/或之后，对成型体的表面进行拉平处理，例如采用刮板或校准杆进行拉平处理。
在有些情况下，还适宜地，例如通过具有或没有热效应的压制、通过研磨、通过涂覆密封层、和/或通过涂覆保护层，对贴面薄片进行后续处理。
如果需要实现高密度的贴面薄片，那么具有优势的是使成型体水平和/或垂直地例如通过压制进行压缩处理。这样的压缩原理上可以在本发明方法的不同时间点上进行。特别适宜地，使对成型体的压缩在将颗粒材料引入到容纳构件中之后、和/或在将表面层和载体层连接之后进行。
通过压缩处理，优选在有热效应的条件下进行，可以使贴面薄片具有明显的光滑表面。在需要的情况下，通过压缩还可以形成这样的结构，例如用于形成圆形或弯曲的表面。如果不要求可视表面具有光滑的外观，贴面薄片的表面还可以在后续处理中进行粗糙处理亦或是结构化处理。
贴面薄片的后续处理还可以通过密封处理和/或涂覆保护层来实现。通过密封处理还可以提供光滑耐用的表面，该表面在需要的情况下还能够防止液体的侵入。
如果涂覆保护层，那么可以使保护层是透明的或是透视的。保护层的涂覆优选在贴面薄片的与载体层相对设置的表面上进行。
保护层的涂覆还可以使用各种常用的将保护层涂覆在材料表面上的方式来实现。对于这些方法例如包括：将由聚合物或前聚物构成的溶液或分散系喷射在材料表面上，聚合物或前聚物在材料表面上的涂覆采用惯用的涂层装置，例如相对行驶的涂层辊、刮板等装置。
优选使保护层的聚合物至少侵入和/或浸透贴面薄片的一部分表面。对此，特别适合采用有利于外部应用的聚合物。这种耐天气变化的聚合物有含氟聚合物、丙烯酸酯聚合物、聚氨酯聚合物、乙烯聚合物和这些聚合物的混合物以及共聚物。对于实现本发明有利的含氟聚合物包括由以下材料组成的聚合物和共聚物，即，三氟乙烯、四氟乙烯、六氟丙烯、单氯三氟乙烯和二氯二氟乙烯。在采用氟烯烃、诸如偏二氟乙烯制成的、前述这些单体的共聚物同样可以应用。用于实现本发明采用的其它所述的实施例，对于含氟聚合物还可以采用聚氟乙烯和聚偏二氟乙烯。含氟聚合物可以为氟化的乙烯/丙烯共聚物，或者是乙烯和氯三氟乙烯的共聚物。用于实现本发明采用的其它含氟聚合物的实施例有：偏二氟乙烯/六氟丙烯、和含有四氟乙烯的偏二氟乙烯/全氟(烷基乙烯基醚)-三聚物和-三元共聚物。
可以采用不同的方式和方法作用于贴面薄片的表面形状。根据本发明的一个优选实施方案，这样作用于贴面薄片的表面形状，即，在将由表面层和载体层构成的复合结构取下之后，在一定时间内，将颗粒材料的未连接的部分除掉。
如果例如将颗粒材料的未连接的部分直接在复合结构取下之后除掉，那么使贴面薄片可以具有相对光滑的表面，也就是说得到较低平的表面形状。
如果相反地需要得到经结构化处理的可视表面，那么根据本发明的另一优选实施方案，在将贴面薄片取下之后，在经过一定时间之后，才将颗粒材料的未连接的部分除掉。以这种方式，还可以使颗粒材料上的这样的部分结合到贴面薄片中，该部分仅具有很小的与粘合剂或粘接剂相接触的表面。采用该实施方案可以制成具有经结构化处理的表面形状的贴面薄片。
采用本发明方法制成的贴面薄片具有优势地适用于不同的应用目的，例如覆盖在盖子、墙壁、地板、门和/或顶棚上。同样，采用本发明方法制成的贴面薄片还具有优势地适用于覆盖亦或是集成设置在家具上，特别是桌面上。此外，贴面薄片还可以用作独立的连接件，例如在载体材料上与玻璃形成连接。视觉上可以这样实现特别适宜的结果，即，使本发明的贴面薄片经由粘接剂与玻璃板在内侧形成连接。在此粘接剂优选是透明的。
尽管本发明的贴面薄片的表面相对于通常使用的大量材料、诸如砂石而仅具有相对较薄的厚度，但是本发明的贴面薄片却自身具有石料的外观。此外，贴面薄片具有挠性，并且能够承受住更大的弯曲和拉伸载荷。由于具有挠性，贴面薄片还可以应用在不平的亦或是可变化的表面上，以提供装饰性的表面。
另外，本发明的贴面薄片相对于传统的材料较轻，因而还可以涂覆在较不稳定的基质上。由此不需要再考虑提供形状稳定的基础层。此外，贴面薄片可以简单快速地进行设置亦或是加工。
作为本发明贴面薄片的基质适合采用不同的材料，诸如木质材料、合成材料、混凝土、水泥(Estrich)、灰浆、绝缘材料、石膏、石膏纤维、金属和类似材料。
贴面薄片的厚度可以根据所需的使用目的在较宽的范围内进行变化。实际试验证明，特别好的结果是，厚度为0.005mm至1cm、优选0.01mm至5mm、特别为0.05mm至3mm。如已经说明的内容，厚度的调整例如可以通过容纳构件的尺寸、以及涂覆量的变化、和/或粘合剂的粘度来控制。
根据本发明的又一优选实施方案，在容纳构件中和/或在颗粒材料中设有至少一个嵌入体。作为嵌入体可以采用不同形状和材料的结构。在其它方法中可以使嵌入体保持在所形成的成型体中，和/或从成型体中除掉。如果使嵌入体保持在成型体中，那么适宜地采用外观装饰性材料，例如贝壳、石料等。如果使嵌入体从成型体中除掉，那么特别适宜地在表面层和载体层连接之前进行该除掉步骤。由于除掉嵌入体而形成的凹陷部可以如上文所述那样用对比剂填充。通过本发明的该变化方案能够实现极其外形优美的贴面薄片。
附图说明
接下来，结合附图所示的实施例对本发明进行详细说明。图中示出了：
图1为将与稳定剂混合的颗粒材料填充到容纳构件中的过程的示意图；
图2为通过成型体的空间位置的变化而在成型体中形成凹陷部的示意图；
图3为通过冲压体的冲压而在成型体中形成凹陷部的示意图；
图4为用对比剂填充凹陷部的示意图；
图5为取下由成型体的表面层和载体层构成的复合结构以形成本发明的贴面薄片的示意图；
图6为用于制造本发明贴面薄片的方法步骤的一个可行顺序的流程图。
具体实施方式
图1示出了用于制造本发明的贴面薄片1的方法步骤。颗粒材料2从储料仓B倒入至容纳构件3中，其中，该容纳构件形成为成型体4。在前述情况下，在倒入之前，颗粒材料2已经与稳定剂相互混合。然而，颗粒材料和稳定剂的混合还可以在晚些时候、例如于容纳构件3中才进行。为实现该目的，可以使稳定剂独立于颗粒材料2、例如从另一个储料仓B导入至容纳构件3中。颗粒材料2和/或稳定剂例如还可以含有添加剂。添加剂既可以与颗粒材料2和/或稳定剂一起填充至容纳构件3中。而且添加剂又可以单独地例如通过储料仓C导入。
图2中示出了，如何通过成型体4的空间位置变化而形成凹陷部5。在此，弯曲的箭头表示容纳构件3的挠性底面6的侧面提升。
图3中示出了，如何通过冲压体7的冲压而在容纳构件3的挠性底面6中形成凹陷部5。
图4中示出了，如何用对比剂填充凹陷部5。
图5中示出了，如何通过取下由成型体4的表面层9和载体层10构成的复合结构而获得本发明的贴面薄片。
图6中示出了用于制造本发明的贴面薄片1的方法步骤的顺序流程图。

Claims (27)

1.一种用于制造贴面薄片(1)的方法，包括以下步骤：
a)将稳定剂与颗粒材料(2)混合；
b)将颗粒材料(2)填充在容纳构件(3)中，该容纳构件形成为成型体(4)；
c)使成型体(4)的至少一个表面层(9)与载体层(10)连接；
d)取下由表面层(9)和载体层(10)构成的复合结构，由此获得贴面薄片(1)。
2.根据权利要求1所述的方法，其特征在于，作为颗粒材料(2)采用天然石料、玻璃、合成材料、木材和/或金属，天然石料优选采用石英、石英砂、砂石、花岗岩、板岩、大理石、凝灰岩。
3.根据权利要求1或2所述的方法，其特征在于，作为颗粒材料(2)采用颗粒物料。
4.根据权利要求1至3中任意一项所述的方法，其特征在于，作为颗粒材料(2)采用的颗粒物料的D50值为0.02mm至1mm，和/或平均颗粒尺寸为0.1mm至1.5mm。
5.根据权利要求1至4中任意一项所述的方法，其特征在于，所述颗粒材料(2)含有防火添加剂、疏水剂、气味吸附剂、有害物质吸附剂、加固材料和/或着色剂。
6.根据权利要求1至5中任意一项所述的方法，其特征在于，作为稳定剂采用水、纤维素、淀粉、糖类、聚乙烯醇、酪蛋白、水玻璃、粘土、皂石、海泡石、瓷土、氧化锌和/或膨胀土。
7.根据权利要求1至6中任意一项所述的方法，其特征在于，在所述成型体(4)中形成至少一个凹陷部(5)，然后使至少一部分该凹陷部(5)用对比剂(8)填充，其中，形成人工结构图案。
8.根据权利要求7所述的方法，其特征在于，所述成型体(4)中的凹陷部(5)通过所述成型体(4)的空间位置变化而形成。
9.根据权利要求8所述的方法，其特征在于，所述成型体(4)的空间位置变化通过所述容纳构件(3)的底面(6)逐点的、优选在一侧的提升而实现。
10.根据权利要求7至9中任意一项所述的方法，其特征在于，所述成型体(4)中的凹陷部(5)通过所述容纳构件(3)的底面(6)的变形而形成，和/或通过设置在所述容纳构件(3)的底面(6)和所述成型体(4)之间的薄膜的变形而形成。
11.根据权利要求10所述的方法，其特征在于，所述底面(6)的变形通过冲压体(7)的冲压而实现。
12.根据权利要求7至11中任意一项所述的方法，其特征在于，采用对比剂(8)，该对比剂通过筛分曲线构成、颗粒尺寸、颜色、结构和/或组成成分与所述颗粒材料(2)相区分。
13.根据权利要求1至12中任意一项所述的方法，其特征在于，采用容纳构件(3)，该容纳构件的底面(6)是可变形的。
14.根据权利要求1至13中任意一项所述的方法，其特征在于，采用容纳构件(3)，该容纳构件的底面(6)由金属或弹性合成材料构成，弹性合成材料优选由聚氨酯、聚氯乙烯和/或硅树脂构成。
15.根据权利要求1至14中任意一项所述的方法，其特征在于，采用容纳构件(3)，该容纳构件含有加固附件和/或填充料。
16.根据权利要求1至15中任意一项所述的方法，其特征在于，采用容纳构件(3)，在该容纳构件的侧壁和/或底面(6)上设有薄膜，该薄膜作为分离层和/或滑动层特别由乳胶、聚异丁烯、聚乙烯、硅树脂、聚氨酯和/或尿素构成。
17.根据权利要求1至16中任意一项所述的方法，其特征在于，采用容纳构件(3)，该容纳构件的底面(6)能够在填充方向上提升。
18.根据权利要求1至17中任意一项所述的方法，其特征在于，采用具有孔隙和/或挠性的载体层(10)。
19.根据权利要求1至18中任意一项所述的方法，其特征在于，作为载体层(10)采用织物、无纺布和/或针织物。
20.根据权利要求1至19中任意一项所述的方法，其特征在于，表面层(9)与载体层(10)的连接利用粘接材料和/或粘合剂来实现。
21.根据权利要求1至20中任意一项所述的方法，其特征在于，在载体层(10)的背向表面层(9)的一侧上涂覆有加强层。
22.根据权利要求21所述的方法，其特征在于，作为加强层采用刨花板和/或中密度纤维板。
23.根据权利要求1至22中任意一项所述的方法，其特征在于，在取下由表面层(9)和载体层(10)构成的复合结构之前和/或之后，对所述成型体(4)的表面进行拉平处理。
24.根据权利要求1至23中任意一项所述的方法，其特征在于，通过压制和/或研磨、通过涂覆密封层、和/或通过涂覆保护层，对所述贴面薄片(1)进行后续处理。
25.根据权利要求1至24中任意一项所述的方法，其特征在于，在所述容纳构件(3)中和/或在所述颗粒材料中设有至少一个嵌入体。
26.一种贴面薄片(1)，根据权利要求1至22中一项或多项所述的方法制成。
27.一种根据权利要求26所述的贴面薄片(1)的用途，用于覆盖在盖子、墙壁、地板、门、顶棚、家具上，特别用于覆盖在桌面上。
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WO2010139723A1 (de) 2010-12-09
EP2437925A1 (de) 2012-04-11
EP2437925B1 (de) 2013-07-31
HK1169080A1 (en) 2013-01-18
DE102009023421A1 (de) 2010-12-09
CN102458802B (zh) 2014-09-17
US20120171428A1 (en) 2012-07-05
UA103680C2 (ru) 2013-11-11

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