CN110121583A - 复合地板产品及其制造方法 - Google Patents

复合地板产品及其制造方法 Download PDF

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Publication number
CN110121583A
CN110121583A CN201680090028.6A CN201680090028A CN110121583A CN 110121583 A CN110121583 A CN 110121583A CN 201680090028 A CN201680090028 A CN 201680090028A CN 110121583 A CN110121583 A CN 110121583A
Authority
CN
China
Prior art keywords
floor board
composite floor
board product
sandwich layer
magnesium
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
CN201680090028.6A
Other languages
English (en)
Inventor
戴瑞克·威尔伯恩
陈建明
张军
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Core Innovations Ltd
Original Assignee
Core Innovations Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Core Innovations Ltd filed Critical Core Innovations Ltd
Publication of CN110121583A publication Critical patent/CN110121583A/zh
Pending legal-status Critical Current

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Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/02—Flooring or floor layers composed of a number of similar elements
    • E04F15/02038—Flooring or floor layers composed of a number of similar elements characterised by tongue and groove connections between neighbouring flooring elements
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/02—Flooring or floor layers composed of a number of similar elements
    • E04F15/08—Flooring or floor layers composed of a number of similar elements only of stone or stone-like material, e.g. ceramics, concrete; of glass or with a top layer of stone or stone-like material, e.g. ceramics, concrete or glass
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • 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
    • B29C39/00—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor
    • B29C39/003—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor characterised by the choice of material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • 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
    • B29C39/00—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor
    • B29C39/02—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor for making articles of definite length, i.e. discrete articles
    • B29C39/021—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor for making articles of definite length, i.e. discrete articles by casting in several steps
    • B29C39/025—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor for making articles of definite length, i.e. discrete articles by casting in several steps for making multilayered articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C39/00—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor
    • B29C39/02—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor for making articles of definite length, i.e. discrete articles
    • B29C39/10—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor for making articles of definite length, i.e. discrete articles incorporating preformed parts or layers, e.g. casting around inserts or for coating articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C39/00—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor
    • B29C39/02—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor for making articles of definite length, i.e. discrete articles
    • B29C39/12—Making multilayered or multicoloured articles
    • B29C39/123—Making multilayered articles
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    • B32B3/02—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products 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 form; Layered products 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
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Abstract

提供了一种适合于室内或室外地板应用的复合地板产品及其制造方法。该复合地板产品包括芯层，该芯层包括：(i)包含氢氧化镁和氯化镁的水合物；(ii)一种或多种分别包含氢氧化镁和硫酸镁的水合物；以及(iii)一种或多种稳定剂。该水合物至少部分地源自氧化镁。该芯层具有不含PVC和其他塑料材料的组成，并被选择以提供一种或多种所需的物理特性，诸如但不限于所需的耐水性、耐久性和热胀冷缩性。该芯层优选具有提供与混凝土相当或相似的热膨胀系数的组成。

Description

复合地板产品及其制造方法
技术领域
本公开涉及一种适合于室内或室外地板应用的复合地板产品及其制造方法。
背景技术
木材通常用作成品地板产品中的主要材料。例如，木材可以其天然形式存在于传统的硬木地板中，或者作为复合和层压地板产品中的背衬或芯层的木纤维成分。但是，包含木材作为主要材料的地板产品易受与湿气相关的问题的影响。例如，湿气的积聚可能导致木地板产品(例如硬木)翘曲或扭曲，或导致层压地板不可逆地膨胀，并且可能限制可使用包含木材作为主要材料的地板产品的环境和状况。
至少部分地由于包含木材作为主要材料的地板产品的限制，地板行业已经见证了复合地板产品的普及。这种复合地板产品中的至少一部分产品提供类似的视觉吸引力，并且具有与传统地板材料(如硬木和石材)相当或比之更优的性能。
有各种类型的复合地板产品。例如，一些复合地板产品具有包含聚氯乙烯(“PVC”)和/或其他塑料化合物的芯层。从已经确立的地板类别中选择的顶层(例如乙烯基产品或塑料层压板)可与芯层结合，从而为地板产品提供装饰和/或耐磨层。复合地板产品包括但不限于豪华乙烯基板(“LVF”)和木塑复合(“WPC”)产品。但是，LVT和WPC产品内的塑料成分通常易受热胀冷缩的影响。这种热胀冷缩可能最终导致或可能使基于塑料产品易于在地板板材之间形成裂缝，从而至少造成美观性和吸引力下降，在地板板材之间积聚尘土和污垢，对产品安装规模造成限制，或者不适合于某些用途或原材料的组合(例如石材或瓷砖)。
商售的复合地板产品通常使用榫槽互锁系统来互连板材。榫槽系统的一个例子是“扣锁”地板系统(例如美国专利6,023,907和美国专利6,006,486所述，这些专利的内容通过完整引用结合在此)。在“扣锁”地板系统中，地板板材的相对侧面铣削有特殊形状的互补卡榫和凹槽，从而地板板材可牢固地锁定在一起，而无需胶水和/或无需将板材粘附到下层地板上。虽然“扣锁”系统已成功应用于木材、复合木材和乙烯基地板产品以及其他相似类别的地板产品，但“扣锁”系统尚未成功地集成到瓷砖和石材地板产品中，这是由于在这些类别中存在着技术难题，包括但不限于瓷砖和石材的脆性。
地板行业一直希望获得经济高效的地板产品和/或易于安装的(例如“扣锁”地板系统)地板产品，这些产品应具有所需的物理特性，例如高耐久性、高耐水性、高耐火性、高防蛀性、高耐菌性和高耐热性和/或耐寒性。但是，具有这些期望特性的地板产品通常难以安装和/或具有较高的制造成本。
传统复合地板产品的一个特殊难题是地板产品的成分倾向于以不同的速率膨胀和收缩，例如由于温度变化或水分含量的原因。更确切地说，某些传统复合地板产品选用的饰面板不会以与地板产品中的其他成分相同或相似的速率膨胀和收缩，从而导致饰面板破裂或以其他方式损坏。例如，在存在湿气的情况下，石材饰面板不会以与木纤维复合背衬层相同的速率膨胀或收缩，这可能导致石材饰面板在背衬层膨胀或收缩时破裂。
传统复合地板产品的另一个难题是如何提供对环境或人类健康无害的产品。例如，一些已知的乙烯基地板产品由再生PVC组成，以减少环境负担。但是，已知的是，这种再生PVC含有对人体健康有害的重金属，如汞、铅和砷。虽然再生PVC在地板产品中的广泛使用已得到遏制，并且由不含重金属的原生PVC取代，但原生PVC的制造消除了使用再生材料的环境效益。另一个例子是，以前常常将甲醛作为粘胶成分引入地板产品中，用于将地板产品的各种组分粘合在一起。但是，从地板产品释放的甲醛会恶化空气质量，并且长时间接触甲醛烟雾也对人类健康有害。
发明内容
本公开涉及一种适合于室内或室外地板应用的复合地板产品及其制造方法。
根据本公开的一个方面，提供了一种复合地板产品，该复合地板产品包括具有第一表面和与第一表面相反的第二表面的芯层，该芯层包括：(a)包含氢氧化镁和氯化镁的第一水合物；(b)一种或多种包含氢氧化镁和硫酸镁的第二水合物；以及(c)一种或多种稳定剂。
该芯层可主要包括包含氢氧化镁和氯化镁的第一水合物和一种或多种包含氢氧化镁和硫酸镁的第二水合物。例如，该包含氢氧化镁和氯化镁的第一水合物和所述一种或多种包含氢氧化镁和硫酸镁的第二水合物的组合可占芯层成分的40-95重量％。
该包含氢氧化镁和氯化镁的第一水合物可以是5Mg(OH)2·MgCl2·8H2O。所述一种或多种包含氢氧化镁和硫酸镁的第二水合物可包括5Mg(OH)2·MgSO4·5H2O，其中该5Mg(OH)2·MgSO4·5H2O可与5Mg(OH)2·MgSO4·3H2O和/或3Mg(OH)2·MgSO4·8H2O组合。
该芯层还可包括包含磷酸镁钾的第三水合物。该芯层还可包括包含磷酸三镁的第四水合物。
该芯层可具有大约为10×10-6/℃的热膨胀系数。
根据本公开的另一个方面，提供了一种制造复合地板产品的方法，该复合地板产品包括具有第一表面和与第一表面相反的第二表面的芯层，该芯层包括包含氢氧化镁和氯化镁的第一水合物、一种或多种包含氢氧化镁和硫酸镁的第二水合物化合物、以及一种或多种稳定剂，该方法包括：(a)在混合器中至少混合氧化镁、氯化镁、硫酸镁、所述一种或多种稳定剂、以及水，从而形成原料浆料；(b)将第一层原料浆料铺展到剔除板上；以及(c)固化第一层原料浆料。
该方法还可包括在固化第一层原料浆料之前在第一层原料浆料上铺设一片稳定材料，并将第二层原料浆料铺展在这片稳定材料上。
本概述不一定描述本公开的所有方面的整个范围。在阅读以下具体实施例的说明后，其他方面、特征和优点对于本领域普通技术人员将变得明显。
附图说明
附图示出了一个或多个示例性实施例，在附图中：
图1是一个实施例的复合地板产品的分解图，该复合地板产品包括顶层、芯层和背衬层；
图2是图1中所示的复合地板产品的芯层的透视图；
图3是另一个实施例的复合地板产品的透视图，该复合地板产品包括芯层和芯层上的耐磨面。
具体实施方式
在下文的说明中使用的“上”、“下”、“向上”、“向下”、“竖向”和“侧向”等方向术语仅用于提供相对基准，不旨在表明对于在使用过程中如何定位或在组件中或相对于环境安装任何物品的任何限制。以单数形式表达的任何元素也包括其复数形式。以复数形式表达的任何元素也包括其单数形式。当在本文中与术语“包括”结合使用时，词语“一”或“一个”的使用可表示“一个”，但也符合“一个或多个”、“至少一个”、以及“一个或不止一个”的含义。
在本文所用的术语“包括”、“具有”、“包含”和“含有”及其语法变化形式是包含性的或开放性的，不排除其他未列举的元素和/或方法步骤。当在本文中与组成、用途或方法结合使用时，术语“基本上由......组成”表示可存在另外的元素、方法步骤，或者可同时存在另外的元素和方法步骤，但是这些增加的项目不会实质性地影响所述组成、方法或用途的作用方式。当在本文中与组成、用途或方法结合使用时，术语“由......组成”排除附加元素和/或方法步骤的存在。
在本文所用的术语“主要”指“最多的成分”。
当后面附有列举的数值时，在本文所用的术语“大约”指该数值加上或减去10％的范围。
在本文所用的术语“水合物”指具有通式aX·cH2O或aX·bY·cH2O的水合离子化合物，其中“X”是第一离子化合物，“Y”是第二离子化合物，“a”是该水合物中的第一离子化合物的分子数，“b”是该水合物中的第二离子化合物的分子数，“c”是该水合物中的水分子的数目。
本公开的实施例涉及一种适合于室内或室外地板应用的复合地板产品(例如地板板材)。该复合地板产品包括芯层，该芯层具有包括以下成分的组成：(i)包含氢氧化镁和氯化镁的第一水合物；(ii)一种或多种分别包含氢氧化镁和硫酸镁的第二水合物；以及(iii)一种或多种稳定剂。该地板产品可包括互锁装置，该互锁装置使地板产品能够与其他地板产品的兼容互锁装置物理地互锁。该地板产品可包括顶部饰面层和背衬层，该顶部饰面层和背衬层附着到芯层上，并将芯层夹在中间。顶部饰面层可以是装饰性饰面板或装饰板，并覆有耐磨层。该地板产品也可具有直接施加到芯层的顶面上的装饰性结构，而不是顶部饰面层，其中耐磨层施加到该装饰性结构上。
在制造该复合地板产品时不将PVC(再生或原生)和/或甲醛结合到该复合地板产品中。因此，芯层具有不含PVC的组成。如本文所考虑的，芯层也不包括任何基于塑料的产品或材料。芯层的组成可提供一种或多种所需的物理特性，例如但不限于所需程度的耐水性、耐久性和热胀冷缩性。该复合地板产品可体现为多块互连的板材、瓷砖或其他较薄且扁平的形状(在此称为“地板构件”)。
氧化镁(“MgO”)是一种天然的金属氧化物矿物，通常能抵抗霉菌、真菌、昆虫和火灾。与可用于类似应用的其他材料的生产相比，MgO的生产可消耗较少能量。例如，可在形成用作普通砂浆中的原始材料的氧化钙(CaO)所需的温度的大约25％温度下从矿石中提取MgO。当将MgO研磨成粉末并与水结合时，可形成水泥状混合物。
地板产品
请参考图1和图2，根据本公开的第一实施例，提供了一种适合于室内或室外地板应用的复合地板产品100，该复合地板产品100包括芯层106，该芯层106包括：(i)包含氢氧化镁和氯化镁的第一水合物；(ii)一种或多种分别包含氢氧化镁和硫酸镁的第二水合物；以及(iii)一种或多种稳定剂。产品100包括顶部饰面层102、第一结合材料104、芯层106、第二结合材料108、以及背衬层110。顶部饰面层102、芯层106和背衬层110通常彼此平行地排列，并通过第一和第二结合材料104、108结合在一起。
顶部饰面层102包括远离芯层106的顶面、以及靠近芯层106的顶面106a的底面。顶部饰面层102由适当的装饰材料制成，包括但不限于塑料层压板、三聚氰胺、石材、瓷砖、木材或软木。这些材料中的某些是天然不透水的；而其他材料可通过本领域已知的技术处理以使其不透水。
顶部饰面层102可选地可包括耐磨层。该耐磨层设计为保护复合地板产品100免受物理损害，例如但不限于复合地板产品100作为地板产品的任何适当用途(例如在复合地板产品100上行走)。耐磨层还可通过其质地和光泽有助于产品的美学吸引力。耐磨面通过本领域已知的技术产生。例如，通过使用淋幕机或辊涂机将水和耐磨材料(例如但不限于氧化铝)的溶液或混合物施加到顶部饰面层102的顶面上并将该溶液或混合物风干或用紫外线固化来形成作为顶部饰面层102的顶部部分的耐磨层。在另一个示例中，耐磨层通过已知的技术形成，例如瓷砖烧制。在另一个示例中，耐磨层可由热熔塑料形成，例如但不限于三聚氰胺。在使用三聚氰胺的示例中，顶部饰面层102可包括热固化的三聚氰胺层。在另一个示例中，顶部饰面层102可通过用紫外线固化来进行涂漆。
顶部饰面层102通过第一结合材料104附着至芯层106。第一结合材料104布置在顶层102与芯层106之间，并且将顶层102的底面附着至芯层106的顶面106a。第一结合材料104可以是本领域中已知的能够将顶部饰面层102附着至芯层106的任何适当材料。在此实施例中所考虑的第一结合材料104是本领域已知的防水粘合剂或粘胶，例如热熔粘合剂或冷固粘合剂。
芯层106包括：(i)包含氢氧化镁和氯化镁的第一水合物；(ii)一种或多种分别包含氢氧化镁和硫酸镁的第二水合物；以及(iii)稳定剂。该包含氢氧化镁和氯化镁的第一水合物和一种或多种分别包含氢氧化镁和硫酸镁的第二水合物的组合占芯层106的成分的40至95重量％。在本文中所考虑的稳定剂占芯层106的成分的1-30重量％。芯层可选地包括抗氧化剂、催化剂、着色剂、增强剂和改性剂。
芯层106的稳定剂是为芯层106提供稳定性的纤维材料。适当的纤维材料包括但不限于：有机纤维材料(例如木材)或其他植物基纤维材料(例如锯末或竹粉)、玻璃基材料(例如涂层玻璃纤维或抗碱玻璃纤维)、玻璃纤维线、化学纤维、塑料纤维、矿物纤维、碳纤维、或者这些材料的任何组合。
芯层106中的粘合剂还能提高芯层106的稳定性和耐久性。该粘合剂包括但不限于氯化镁(作为一种或多种水合化合物的一部分结合在最终地板产品中)、硫酸镁(作为一种或多种水合化合物的一部分结合在最终地板产品中)、磷酸钾、粉煤灰和活性炭。
该抗氧化剂可以是金属氧化物矿物或石灰石基衍生物。例如，该抗氧化剂可以是氧化镁，在地板产品100的制造过程中，该氧化镁转化为氢氧化镁基水合物。
该着色剂可选自任何适当的染料、油墨、氧化物矿物(例如氧化铁)或其他着色剂，例如但不限于碳。
在芯层106的制造过程中使用催化剂以改善芯层106的凝固时间。该催化剂可以是本领域已知的任何适当催化剂，并且可在制造过程中消耗。
该改性剂在芯层106的制造过程中用于提高制造工艺的效率并增强芯层106的强度和稳定性。适当的改性剂包括但不限于磺酸盐(例如石脑油磺酸钠)、硫酸盐(例如乙醇醚硫酸钠、硫酸铝)，脂肪醇聚氧乙烯醚、以及本领域已知的改性剂聚合物。在制造过程中可能会消耗改性剂。
在一些实施例中，芯层106还包括填充材料，该填充材料降低芯层106的密度和重量，而不损害芯层106的所需特性。一种示例性填充材料是珍珠岩。
芯层106通常具有以下材料成分：
例如，地板产品100可包括包含氢氧化镁的水合物，该水合物占地板产品100的重量百分比为40-95％、45-95％、50-95％、55-95％、60-95％、或这些值之间的任何特定百分比。
在第一示例中，芯层106具有以下材料组成：
在第二示例中，芯层106具有以下材料组成：
具有表1、2或3中所列的组成之一的芯层106优选具有大约10×10-6/℃的热膨胀系数，该热膨胀系数与混凝土的热膨胀系数大致相当或相似。这样的热膨胀系数相当于芯层106的长度在给定的60摄氏度温度范围内在24小时之中大约每30.5米(100英尺)伸长/收缩大约1.7厘米。对于温度范围不太极端的室内产品应用，预计复合地板产品100的长度的任何变化通常可忽略不计，并且预计不会影响复合地板产品100在其寿命期内的性能和/或美学吸引力。
对于温度变化极端的户外应用，选择的任何饰面板或其他顶部饰面层材料应具有相似的热膨胀系数，以确保不会发生开裂或其他损坏。例如，石材饰面板具有与芯层106相似的膨胀系数，因此可用作针对户外应用的顶部饰面层的饰面板。这样能有利地减小补偿地板产品所经历的任何热膨胀的膨胀间隙或完全消除这种膨胀间隙。
芯层106的相对稳定性和低热膨胀系数允许具有与芯层106相似的低热膨胀系数的脆性层结合到芯层106的顶面106a上，同时最大限度地降低因芯层106的热胀冷缩而开裂的风险。该脆性层包括但不限于薄陶砖、瓷砖或石材。此外，芯层106的高密度和稳定的竖向层结构特征可允许其用作地板芯层，并铣制有“榫槽”型免胶连接系统。
此外，预计具有表1、2或3中的组成的芯层106还具有其他所需的特性，包括：
·耐温性：预计芯层106在300℃以下的温度下不会变形，从而允许通过热压(例如使结合材料(例如结合材料104、108)热激活)来形成复合地板产品。芯层106也可作为用于层压地板或粉末涂层技术的芯层106。
·耐水性：预计芯层106在与水接触时基本上不会改变尺寸或形状，因此可用于高湿度的区域(例如浴室和厨房)。
从结构上说，芯层106是长条基板，在两个或更多直边的边缘处具有互连装置，该互连装置将一块复合地板产品100与其他块地板产品100物理地互连。在一个实施例中，每块地板产品100包括如图2所示的“榫槽”系统(例如“扣锁”系统)，该系统允许各块复合地板产品100连接并安装在一起，而无需使用粘合剂(例如粘胶)。在这种“榫槽”系统中，芯层106包括沿着芯层106的第一侧的长度侧向延伸的凹部106b(例如凹槽)和凹部唇缘106c、以及沿着芯层106的相对的第二侧的长度侧向延伸并从芯层106突出的突出部106e(例如舌片)。第一块复合地板产品100的凹部106b配置为接收相邻的第二块复合地板产品100的突出部106e，从而第一块和第二块复合地板产品100机械地结合在一起。凹部唇缘106c有助于保持第一块复合地板产品100的凹部106b与相邻的第二块复合地板产品100的突出部106e的结合。芯层106还包括在芯层106的凹部106b与突出部106e之间延伸的侧面106d。在其他实施例中，相邻的各块复合地板产品100通过“扣锁”系统和粘合剂结合在一起，以锁定相邻各块复合地板产品100之间的接头。在其他实施例中，芯层106包括角度折叠系统，其中板材的长边接合后折叠到位，并在折叠运动期间在长边被接合的同时短边也被接合(例如参见EP1,415,056)。在其他实施例中，地板产品100不具有“榫槽”或“扣锁”型系统，而是具有粘性背面，该粘性背面可直接贴装并附着到地板产品100下的地面上。
可选地，沿着芯层106的纵向轴线在芯层106中布置一片稳定材料(未示出)，例如玻璃纤维板，以便为芯层106提供稳定性。该稳定材料可在芯层形成过程中嵌入芯层106中。在其他实施例中，可在顶层102与芯层106之间或芯层106与背衬层110之间布置一片稳定材料，或者在顶层102与芯层106之间以及芯层106与背衬层110之间分别布置一片稳定材料。
背衬层110通过第二结合层108结合至芯层106的底面，并且可由本领域中已知的适当材料制成。例如，背衬层可由软木、泡沫、毛毡、发泡或橡胶材料制成。背衬层110具有各种潜在的应用。在一个示例中，背衬层110提供一个缓冲层，该缓冲层能克服或减少下层地板中的微小缺陷(例如表面不平坦)的影响。在另一个示例中，背衬层110用于减少或消除透过复合地板产品100传递至下层地板的噪音量。包括预先结合至芯层106的背衬层110的复合地板产品100能减少安装复合地板产品100所需的时间和人工。在其他实施例中，背衬层110不是预先结合到芯层106中的。在其他实施例中，背衬层100是“剥离和粘贴”型。在其他实施例中，复合地板产品100不包括背衬层110。优选背衬层110是防水的，并由闭孔泡沫材料或天然防水材料制成，例如但不限于软木。在其他实施例中，背衬层110可以是不防水的。
复合地板产品100还可包括装饰层，该装饰层提供复合地板产品的美观效果或美学吸引力。该装饰层可以是一片装饰性印刷纸，该装饰性印刷纸通过数字方式或通过轮转凹版印刷方式直接印刷到顶部饰面层102上。
请参考图3，根据本公开的第二实施例，提供了一种不包括顶层的复合地板产品300。相反，芯层306的顶面306a被直接处理为用作装饰和耐磨面。芯层306上的装饰表面通过本领域已知的技术产生。例如，顶面306a可在芯层306本身的混合物中呈现装饰效果，并添加或混合有染料和/或着色剂以形成所需颜色。顶面306a可选地用漆或釉料密封，该漆或釉料可以是紫外线固化或热固化的。顶面306a上的耐磨面也可通过本领域已知的技术产生，例如但不限于压板、多道印刷和热熔技术。在一个示例中，使用淋幕机或辊涂机将溶液或混合物涂装到顶面306a上，并使该溶液或混合物在顶面306a上干燥，从而在芯层306上形成耐磨面。该溶液或混合物包含耐磨材料，例如但不限于氧化铝。在另一个示例中，耐磨面通过热量或紫外线固化到产品300的顶面上。
复合地板产品100、300通常按典型的地板尺寸制造。对于模仿木地板外观的设计，复合地板产品的宽度通常为2.5英寸至12英寸，长度为24英寸至96英寸。对于模仿瓷砖和/或石材外观的设计，复合地板产品通常形为正方形或矩形。方形的复合地板产品通常具有12英寸×12英寸至48英寸×48英寸的尺寸。复合地板产品的厚度取决于复合地板产品的应用。典型厚度通常为4毫米(0.16英寸)至20毫米(0.79英寸)。
地板产品的芯层的制造
芯层是通过将氧化镁和稳定纤维材料及粘合剂研磨成粉末来制造的。其他助剂(包括抗氧化剂、催化剂、稳定剂、着色剂、增强剂、填充材料和改性剂)也可与氧化镁、稳定纤维材料和粘合剂一起研磨。可在将氧化镁和稳定纤维材料及粘合剂研磨成粉末的过程之中或之后加入水。
可将一批原料(例如下表4、5和6中的任何一个列出的材料)在适当的混合器(例如但不限于工业混合器)中混合，以产生一批原料浆料，在成形工位收集该原料浆料。混合在室温下进行，每批持续5-15分钟。
在地板产品的芯层的示例性制造过程中，将剔除板或板条(在其上形成芯层)供送到成形生产线上。首先将防粘剂施加到剔除板的表面上。该防粘剂防止随后施加到剔除板上的任何材料粘附到剔除板上。适当的防粘剂是本领域中已知的，包括但不限于硅油和皂类。将由氧化镁、稳定纤维材料和粘合剂组成的第一层原料浆料倾倒在覆有防粘剂的剔除板上并摊平。第一层原料浆料还可包含其他助剂，包括抗氧化剂、着色剂和增强剂。
将一片稳定材料(例如但不限于玻璃纤维板)铺设在第一层原料浆料上。将由氧化镁、稳定纤维材料和粘合剂组成的第二层原料浆料倾倒稳定材料上并摊平。第二层原料浆料还可包含其他助剂，包括抗氧化剂、着色剂和增强剂。
然后，在工业尺寸的干燥烘箱中，在使每个固化芯层的内部温度达到大约60℃的环境中对由剔除板支撑的形成芯层的未固化原料浆料层固化大约12小时。随后将固化的芯层从剔除板上取下，修整并打磨至适当的尺寸，并进行涂装。将固化的芯层在大约10-30℃温度下进一步冷却大约24小时，以释放固化的芯层106内的内应力。
虽然加热能加速固化过程，但是不需要在固化过程中施加热量。在制造在此所考虑的芯层时不需要挤制。
在其他示例中，在芯层内不包含稳定材料片。
能够设想的是，在本说明书中论述的任何方面或实施例的任何部分可与本说明书中论述的任何其他方面或实施例的任何部分一起实施或组合。虽然在上文中说明了一些特定实施例，但是应理解，其他实施例也是可能的，并且应包括在本发明的范围内。对本领域技术人员来说显而易见的是，能够对上述实施例进行各种修改和调整。

Claims (25)

1.一种复合地板产品，包括具有第一表面和与所述第一表面相反的第二表面的芯层，所述芯层包括：
(a)包含氢氧化镁和氯化镁的第一水合物；
(b)一种或多种包含氢氧化镁和硫酸镁的第二水合物；和
(c)一种或多种稳定剂。
2.根据权利要求1所述的复合地板产品，其中所述包含氢氧化镁和氯化镁的第一水合物和所述一种或多种包含氢氧化镁和硫酸镁的第二水合物的组合在重量上占所述芯层的成分的40-95％。
3.根据权利要求1或2所述的复合地板产品，其中所述包含氢氧化镁和氯化镁的第一水合物是5Mg(OH)2·MgCl2·8H2O。
4.根据权利要求1至3中任一项所述的复合地板产品，其中所述一种或多种包含氢氧化镁和硫酸镁的第二水合物至少包括5Mg(OH)2·MgSO4·5H2O。
5.根据权利要求4所述的复合地板产品，其中所述一种或多种包含氢氧化镁和硫酸镁的第二水合物还包括5Mg(OH)2·MgSO4·3H2O、3Mg(OH)2·MgSO4·8H2O、或者同时包括两者。
6.根据权利要求1至5中任一项所述的复合地板产品，还包括包含磷酸镁钾的第三水合物。
7.根据权利要求6所述的复合地板产品，其中所述包含磷酸镁钾的第三水合物是MgKPO4·6H2O。
8.根据权利要求1至7中任一项所述的复合地板产品，还包括包含磷酸三镁的第四水合物。
9.根据权利要求8所述的复合地板产品，其中所述包含磷酸三镁的第四水合物是Mg3(PO4)2·3H2O。
10.根据权利要求1至9中任一项所述的复合地板产品，还包括附着至所述芯层的所述第一表面的饰面层。
11.根据权利要求10所述的复合地板产品，其中所述饰面层是包括耐磨材料的耐磨面，所述耐磨材料直接在所述芯层的所述第一表面上施加并干燥。
12.根据权利要求11所述的复合地板产品，其中所述耐磨材料是氧化铝。
13.根据权利要求10所述的复合地板产品，其中所述饰面层包括：(i)通过粘合剂结合至所述芯层的所述第一表面的装饰层；以及(ii)包括耐磨材料的耐磨面，所述耐磨材料直接在所述装饰层上施加并干燥。
14.根据权利要求13所述的复合地板产品，其中所述耐磨材料是氧化铝。
15.根据权利要求1至14中任一项所述的复合地板产品，还包括附着至所述芯层的所述第二表面的背衬层。
16.根据权利要求15所述的复合地板产品，其中所述背衬层由闭孔泡沫材料或天然防水材料制成。
17.根据权利要求15或16所述的复合地板产品，其中所述背衬层通过粘合剂附着至所述芯层的所述第二表面。
18.根据权利要求1至17中任一项所述的复合地板产品，其中所述芯层具有10×10-6/℃的热膨胀系数。
19.根据权利要求1至18中任一项所述的复合地板产品，其中所述芯层包括第一边缘和第二相对边缘，所述第一边缘具有横向延伸到所述芯层中的凹槽，所述第二相对边缘具有沿所述第二相对边缘侧向延伸并从所述芯层突出的突出部，其中所述凹槽和所述突出部具有成形为形成扣锁紧固系统的轮廓。
20.根据权利要求1至19中任一项所述的复合地板产品，其中所述一种或多种稳定剂包括木材、植物基材料、有机纤维材料、玻璃纤维、玻璃纤维线、玻璃基材料、锯末、竹粉、化学纤维、耐碱玻璃纤维、塑料纤维中的至少一种或者它们的任何组合。
21.一种制造复合地板产品的方法，所述复合地板产品包括芯层，所述芯层包括包含氢氧化镁和氯化镁的水合物、一种或多种包含氢氧化镁和硫酸镁的水合物、以及一种或多种稳定剂，所述方法包括：
(a)在混合器中至少混合氧化镁、氯化镁、硫酸镁、所述一种或多种稳定剂、以及水，从而形成原料浆料；
(b)将第一层原料浆料铺展到剔除板上；以及
(c)固化所述第一层原料浆料。
22.根据权利要求21所述的方法，还包括在固化所述第一层原料浆料之前在所述第一层原料浆料上铺设一片稳定材料，并将第二层原料浆料铺展在所述一片稳定材料上。
23.根据权利要求22所述的方法，还包括固化所述第二层原料浆料。
24.根据权利要求21至23中任一项所述的方法，还包括大约60℃的固化温度。
25.根据权利要求27所述的方法，还包括大约12小时的固化时间。
CN201680090028.6A 2016-10-11 2016-10-11 复合地板产品及其制造方法 Pending CN110121583A (zh)

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