CN102781668A - 具有装饰性耐磨表面的纤维基镶板 - Google Patents

具有装饰性耐磨表面的纤维基镶板 Download PDF

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CN102781668A
CN102781668A CN2010800608695A CN201080060869A CN102781668A CN 102781668 A CN102781668 A CN 102781668A CN 2010800608695 A CN2010800608695 A CN 2010800608695A CN 201080060869 A CN201080060869 A CN 201080060869A CN 102781668 A CN102781668 A CN 102781668A
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J·雅各布松
G·齐格勒
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Valinge Innovation AB
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Abstract

本发明涉及一种建筑镶板的生产方法，该方法包括步骤：将包括纤维（14）、粘合剂（19）和耐磨颗粒（12）的混合物的层（5）施加到载体（6）上；使用压花模板（2a，2b）压制所述层（5），从而提供压花部分（4）；用装饰性物质（3）填充所述压花部分。

Description

具有装饰性耐磨表面的纤维基镶板
技术领域
本发明总体涉及用于建筑镶板、优选用于地板镶板的具有耐磨表面的纤维基镶板领域。本发明涉及具有这种耐磨表面的建筑镶板，并尤其涉及生产这种镶板的生产方法。
背景技术
本发明特别适用于浮式地板，浮式地板由地板镶板形成，地板镶板包括芯部和装饰性耐磨实心（solid）表面层，装饰性耐磨实心表面层包括纤维、粘合剂和耐磨颗粒，如WO 2009/065769所述。因此下面对现有技术、已知系统的问题以及本发明的目的和特征的描述（作为非限制性示例）首先针对此应用领域，特别是类似于传统木质纤维基层压地板的地板领域。本发明不排除向下胶合在底层地板上的地板。
应强调的是，本发明可用于生产整个镶板或单独的表面层，该表面层例如施加在芯部上以形成镶板。本发明还可用于例如墙面镶板、天花板和家具构件等应用。
基于木质纤维的直接压制的层压地板通常包括由6-12mm的纤维板制成的芯部、由层压板制成的0.2mm厚的上部装饰性表面层以及由层压板、塑料、纸或类似材料制成的0.1-0.2mm厚的下部平衡层。
层压地板的表面层的特征在于，装饰性和耐磨性一般通过两个单独的层获得，其中一层位于另一层上。
印刷装饰纸和覆盖层用三聚氰胺树脂浸渍并在热和压力作用下层压到木质纤维基芯部上。
最近，已开发出具有实心表面的新型的“无纸”地板类型，实心表面包括纤维、粘合剂和耐磨颗粒的充分均匀的混合物。
耐磨颗粒优选是氧化铝颗粒，粘合剂优选是热固性树脂、例如氨基树脂，纤维优选是木质基的。其它合适的耐磨颗粒是例如硅石或者碳化硅。在大多数应用中，均匀的混合物中包含装饰性颗粒，例如颜料。通常，所有这些材料优选在干燥状态下作为混合粉末施加在HDF（高密度纤维板）芯部上并在热和压力作用下固化形成0.1-1.0mm的实心层。
较已知技术并尤其是较传统的层压地板可获得几个优点：
●作为均匀混合物的耐磨表面层可以做得更厚，获得了高得多的耐磨性。
●通过使用深压花和单独的装饰性材料，可获得新颖且非常高级的装饰效果，装饰性材料可融入均匀的表面层并与压花协调。
●通过更厚的并且具有更高密度的均匀的表面层，可获得提高的抗冲击性。
●均匀的表面层可包含对声音和湿气特性具有正影响的颗粒。
●由于可使用低成本甚至回收的材料以及可省略一些生产步骤，可以降低生产成本。
粉末技术非常适于生产装饰性表面层，这种表面层是石材和陶瓷的一种翻版。然而，制造例如木质装饰的设计更加困难。
如果类似例如木质地板的高级设计可如在本申请中所述的以更具成本效益的方式生产，则粉末基地板可达到高得多的市场份额。
术语定义
下文中，已安装的地板镶板的可视表面称为“前侧面”，该地板镶板的面向底层地板的相对侧面称为“后侧面”。“表面层”是指给予镶板装饰特性和耐磨性并且在最靠近前侧面处施加于芯部上并优选覆盖地板块的整个前侧面的所有层。“装饰性表面层”是指主要用于给予地板装饰性外观的层。“耐磨层”涉及主要用于提高前侧面的耐久性的层。
“水平面”是指平行于表面层的外部部分延伸的平面。“水平地”是指与水平面平行，“竖直地”是指与水平面垂直。“上”是指朝向前侧面，“下”是指朝向后侧面。
现有技术及其问题
图1示出新型“无纸”地板类型的已知实施例，该地板具有实心表面5，该实心表面5包括纤维（优选木质纤维14）、小而硬的耐磨颗粒12、12’和粘合剂19的混合物。木质纤维通常未经提纯且与在HDF和刨花板中所用的是同一种类型。它们包括天然树脂，例如木质素。耐磨颗粒（12，12’）优选是氧化铝颗粒。表面层还优选包含颜料15或其它装饰性材料或化学物质。
优选的粘合剂是三聚氰胺或尿素甲醛树脂。可以使用任何其它粘合剂，优选合成热固性树脂。实心层5通常以干粉末形态施加到木质基芯部6、例如HDF上，并在热和压力作用下固化。粘合剂19渗透入芯部的上部部分34中并将实心表面层连接到芯部上。
高级装饰图案可以使用例如数码喷墨装置成行地施加到散布的或预先压制的表面上，数码喷墨装置允许墨水渗透入粉末。主要缺点是，需要在压制前印刷，并且如果印刷图案应该与由压制板形成的压花结构相协调，则需要特殊定位。
可使用集成的印刷和设计“印章”的方法，其中，压花压制模板包括凸起，所述凸起例如通过橡胶辊覆盖有所选择的油漆，所述橡胶辊将油漆仅施加到凸起上，而不施加到位于凸起之间的较低部分处的模板部分上。在压制期间，可以将所选择的油漆仅施加到表面层的被压制得低于顶部表面的部位，可获得配合很好的设计和结构。主要缺点是，必须将墨水施加到热的压制板上，并且必须将辊子插入印制机。这将对印制能力有负面影响。
发明内容
本发明实施例的总体目的是提供一种建筑镶板，优选具有实心表面的地板镶板，该建筑镶板具有比已知建筑镶板更好的设计特性和/或成本结构。
本发明实施例的第一目的是提供一种实心层压镶板，优选地板镶板，该镶板具有优选与压花结构协调的高级表面设计，高级表面设计可以与高耐磨性相结合。
本发明实施例的第二目的是提供一种生产高级表面设计的具有成本效益的方法。
根据本发明的第一方面，提供一种生产方法，该方法包括以下步骤：
●将包括纤维、粘合剂和耐磨颗粒（优选氧化铝颗粒）的混合物的层施加到载体上。
●通过利用压花模板压制混合物，在所述层上提供压花部分。
●使用装饰性物质填充所述压花部分。
所述压制可作为在主压制之前的预压制，主压制在热和压力作用下使表面固化。在该替代方案中，装饰性物质在预压制之后但在主压制之前施加。优点是，即使光滑平面也可制成具有结合在实心层压表面中的装饰性物质。预压制的表面当然也可以在主压制步骤中使用压花模板压制。
也可以在主压制步骤之后施加装饰性物质。在此情况下，压花结构可被保持。
这两个原理可以结合，可形成几个压制步骤，例如，预压制、主压制和辅助压制，装饰性物质可以在主压制和/或辅助压制步骤之前和/或期间和/或之后施加。
附图说明
以下将结合优选实施例并且更具体地参照示例性附图说明本发明，其中：
图1示出已知的实心层压表面；
图2a-d示出形成装饰性表面的方法；
图3a-c示出形成装饰性表面的另一方法。
具体实施方式
图2a-2d示出根据本发明的为了形成建筑镶板1而生产装饰性表面5的生产方法。将纤维、粘合剂和耐磨颗粒的混合物5施加到载体6上，该载体6优选是木质基芯部，如图2a所示。混合物优选以粉末形态通过散布设备施加，并可优选包含装饰性物质，例如提供基本颜色的颜料。
如图2b所示，通过使模板2a预压入未固化的表面混合物5中，形成压花部分4。装饰性物质3施加到压花部分内（图2c）,然后在主压制步骤中压制表面，在该主压制步骤中，混合物5固化成其最终形状，如图2d所示。
可用多种方式施加装饰性物质，例如应用散布结合振动，其中，装饰性物质自动定位到压花部分内。在压花部分外部的多余材料被例如机械地或用压缩空气和类似的方法清除后，装饰性物质也可以作为部分或全部覆盖表面的层施加。
合适的装饰性物质是颜料、油漆、墨水、膏和预染色的纤维。
装饰性物质优选也包含耐磨颗粒和粘合剂。
图3a-3c示出根据本发明的另一方法。表面5以粉末形态（图3a）施加，并且在主压制步骤中被压制，从而在固化的表面中形成压花部分4。
压花部分填充有装饰性物质，装饰性物质可填充全部或部分压花部分，以便在设计和压花之间获得很好的协调。
装饰性物质可利用各种已知方法在施加到压花部分之后或期间固化。不排除进一步的压制步骤。
不排除使用纸基的覆盖层或以湿或干形态施加的包含耐磨颗粒的覆盖层，这会增加耐磨性。

Claims (8)

1.一种制造建筑镶板（1）的方法，该方法包括以下步骤：
●将包括纤维（14）、粘合剂（12）和耐磨颗粒（12）的混合物的层（5）施加到载体（6）上；
●利用压花模板（2a，2b）压制所述层（5），从而提供压花部分（4）；
●使用装饰性物质（3）填充所述压花部分。
2.根据权利要求1所述的方法，其特征在于，所述镶板是地板镶板。
3.根据权利要求1或2所述的方法，其特征在于，所述步骤还包括在填充所述压花部分之后的附加压制步骤。
4.根据权利要求1-3中任一项所述的方法，其特征在于，所述载体是HDF板。
5.根据权利要求1-4中任一项所述的方法，其特征在于，所述混合物中的耐磨颗粒是氧化铝颗粒。
6.根据权利要求1-5中任一项所述的方法，其特征在于，所述装饰性物质包括耐磨颗粒和粘合剂。
7.根据权利要求1-6中任一项所述的方法，其特征在于，所述装饰性物质包括颜料和木质纤维。
8.根据权利要求1-7中任一项所述的方法，其特征在于，所述装饰性物质中的耐磨颗粒是氧化铝颗粒。
CN2010800608695A 2010-01-15 2010-12-22 具有装饰性耐磨表面的纤维基镶板 Pending CN102781668A (zh)

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