CN110325362A - 适于组装防水地板或墙壁覆盖物的面板、生产面板的方法 - Google Patents
适于组装防水地板或墙壁覆盖物的面板、生产面板的方法 Download PDFInfo
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Abstract
一种面板,适于由多个所述面板组装防水地板或墙壁覆盖物,其中所述面板具有基本平坦的顶表面和基本平坦的底表面,所述面板具有多个层的层压结构,所述层包括:柔性的芯层,所述芯层基本上由密度相对较低、设有气穴形式的空隙的材料构成,以及包括支撑层的刚性顶层,所述支撑层基本上由密度相对较高、几乎没有气穴的材料构成,其中所述芯层的厚度小于所述支撑层的厚度,优选地为0.5或更小的比率,更优选地为0.5至0.10之间的比率。
Description
技术领域
本发明的第一方面涉及一种面板,其适于由多个所述面板组装防水地板或墙壁覆盖物,其中所述面板具有基本平坦的顶表面和基本平坦的底表面,所述面板具有多个层的层压结构,这些层包括:
-柔性的芯层,其基本上由设有气穴形式的空隙并且因此密度相对较低的材料构成,以及
-包括支撑层的刚性顶层,该支撑层基本上由几乎没有气穴并且因此密度相对较高的材料构成,并且其中芯层的密度低于顶层的密度。
本发明的第二方面涉及生产根据本发明第一方面的面板的方法。
背景技术
在地板和墙壁覆盖物领域中,最初地,面板是基于木材或其衍生物形成的。然而,主要的缺点是这种材料的吸湿性,该吸湿性降低了其作为防水覆盖物的适用性,并且影响了这种面板的寿命和耐久性。
作为一种重要的替代方案,在美国专利US9212494中,提出了一种基于来自聚乙烯基化合物的层的面板。使用这些化合物是有利的,因为它们是防水的,并且重量相对较轻。所提出的面板具有根据夹层类型的多个层的层压结构:它包括顶层、基底层(实际上是中心的主层)和背衬层。基底层的密度相对较低,并且由泡沫合成材料制成。顶层和背衬层由聚乙烯基化合物制成,其中至少顶层具有比基底层更高的密度。因此,基底层具有比顶层更柔韧的属性,而顶层具有更加刚性的特性。
在该面板中,基底层的厚度具有这样的尺寸:其允许舌片和凹槽类型的互连轮廓的设置,从而所述互连轮廓形成基底层整体的一部分。
关于基底层的施加密度,US494教导了为了达到精细平衡:一方面,密度应当足够高以避免与下面的表面的任何不平整相关的迁移效应朝向面板的上表面传递。此外,要避免层的太软的特性,以防止在使用期间施加在面板的上表面上的力引起变形。此外,声音的传播成为使用太软的材料用于面板中的问题。另一方面,密度不应变得太高,以避免太硬的面板在面板和下面的表面之间、在存在任何不平整的点处产生共鸣箱。因此,US494教导了基底层应具有450kg/m3至900kg/m3之间的平衡密度。
就其对终端用户的实用性而言,US494中提出的面板确实实现了足够的噪声水平降低和足够的防水质量,但是面板的其他特性例如刚性和压痕性能受到损害,到达实际上不足或不令人满意的程度。
总之,当总览现有技术中已知的面板时,本领域仍然普遍需要开发一种进一步改进的面板,其不仅具有令人感兴趣的防水和声学特性,而且还具有足够的刚性和/或抗压痕性能。
发明内容
在上面的背景下,本发明的目的是通过开发一种技术解决方案来满足上述普遍需要,该技术解决方案完全或部分地消除了与现有技术中已知的面板有关的一个或多个缺点。
本发明的上述目的通过提供根据上述前序部分的面板来满足,其中芯层的厚度小于支撑层的厚度,优选地为0.5或更小的比率,更优选地为0.5至0.10之间的比率。最优选地,该比率在0.5至0.25之间。
本发明人已经发现,通过与支撑层相比减小芯层的厚度,可以实现具有足够的防水和声学特性的面板,其同时具有足够的刚性和/或足够的抗压痕性能。
此外还获得了额外的技术优势,因为面板整体不易变形,即,通过在面板中使用相对薄的芯层而显著减少了因在使用期间可能经受的温度和湿度循环而导致的卷曲。
优选地,在根据本发明的面板中,支撑层直接或间接地设置在芯层的顶侧上。
例如,可以通过施加足够的热量和压力将支撑层层压到芯层上,或者可以替代性地通过在这两个层之间施加粘合剂层而将支撑层胶粘到彼此上。
特别优选地,在根据本发明的面板中,芯层的厚度范围为0.5mm至3.0mm,优选为0.8mm至1.5mm。
进一步特别优选地,在根据本发明的面板中,支撑层的厚度范围为2.0mm至8.0mm,优选为2.5mm至4.0mm。
应当注意,在本发明的背景下,面板的最大总厚度在4mm至15mm的范围内,更优选地在4.5mm至8.0mm的范围内。
在根据本发明的面板的优选实施例中,芯层的密度为100kg/m3至300kg/m3。已经发现,根据本发明的目的,该密度在实现所有所需性能方面取得了适当的平衡。
在根据本发明的面板中,芯层材料中的固有空隙可以具有闭孔和/或开孔结构的形式。
特别地,在根据本发明的面板中,优选地,芯层的材料具有泡沫结构。泡沫结构基本上由其中存在闭孔和/或开孔的基质组成。泡沫结构通常通过在熔体形成并硬化成其最终形状之前将发泡剂添加到熔体中而获得。由于泡沫结构的密度低于实心结构,因此芯层的重量进一步减小,这对于面板是有利的。此外,与实心结构相比,泡沫结构具有改善了声音阻尼特性的优点。
在根据本发明的面板的另一优选实施例中,支撑层的密度为至少1200kg/m3,更优选为至少1400kg/m3,最优选为至少1600kg/m3。取决于面板的具体构造,适当的密度通常在1800kg/m3至2100kg/m3的范围内。
因此,支撑层在很大程度上有助于提供足够的刚性和抗压痕性能。
此外,在根据本发明的面板中,当根据EN310标准测量时,支撑层具有至少2000N/mm2的刚度。
当根据EN310标准测量时,根据本发明的面板优选具有至少2000N/mm2的总体刚度。优选地,总体刚度应在3000N/mm2至6000N/mm2的范围内,更优选地在4000N/mm2至5000N/mm2的范围内(根据EN310标准测量)。
在根据本发明的面板中,优选的是,芯层的材料包括来自PE、EVA、PS、PP、PU或三聚氰胺的泡沫材料,或者软木。
在根据本发明的面板中,优选的是,支撑层的材料包括热塑性材料,优选为PVC,更优选为几乎不含增塑剂并含有CaCO3作为填充材料的PVC,其中最优选地,CaCO3以60wt.%的含量存在。
在根据本发明的面板的另一优选实施例中,支撑层的材料包含增强材料,例如玻璃纤维网或网状物。
因此,考虑到其在根据本发明的面板中的预期用途,支撑层得到进一步加强。
此外,在根据本发明的面板中,顶层优选包括耐磨层和在支撑层上方的装饰层,该耐磨层可选地设有涂层。
这些附加的层使面板更适于其作为防水地板或墙壁覆盖物的预期用途。
涂层可以是由氨基甲酸乙酯、丙烯酸或油化合物制成的材料,并且其厚度优选为0.05mm至0.10mm。耐磨层可以由包括PVC在内的热塑性化合物制成,或者由木材、纸或浸渍有三聚氰胺的纸制成。耐磨层的厚度优选为0.15mm至0.50mm。装饰层的厚度约为0.05mm至3.0mm,并且由任何合适的材料制成,例如PVC、木材、纸、浸渍有三聚氰胺的纸、以及软木。此外,装饰层设有可以通过数字印刷形成的装饰面。
如通常在面板的顶层中所应用的那样,顶表面处的边缘可设置有在耐磨层上延伸的斜边。
根据优选实施例,在面板中,芯层的底侧直接或间接地设置有背衬层。
背衬层有助于平整放置面板的下方表面的任何不平整,并且可以有助于面板的刚性。另外,背衬层可具有额外的特征,例如抓握效果和抗菌特性。
背衬层的优选厚度为0.5mm至5.0mm,更优选为0.8mm至2.0mm。背衬层的材料是热塑性材料、木材、纸或浸渍有三聚氰胺的纸。
优选地,背衬层的材料是PVC,更优选为几乎不含增塑剂并含有CaCO3作为填充材料的PVC,其中最优选地,CaCO3以60wt.%的含量存在。
可替代地,背衬层的材料可以是柔性乙烯基化合物,其增塑剂含量为至少5wt.%。
特别优选地,根据本发明的面板具有至少四个基本上线性的侧边缘,所述侧边缘优选地具有矩形设计。
该设计使得面板最适合于由多个面板组装地板或墙壁覆盖物。
在根据本发明的面板中,特别优选的是,线性的侧边缘包括至少一对相反的侧边缘,这些侧边缘设置有互连耦合装置,用于将一个面板互连在另一个面板内。
这样的“浮动”覆盖物可以通过在其连接侧将各个面板彼此互连来组装,不需要使用诸如粘合剂之类的附加耦合装置。
优选地,根据本发明的面板包括两对相反的侧边缘,这些侧边缘设有互连耦合装置。
当根据本发明的面板设置有互连耦合装置时,这些装置优选地包括舌片和凹槽,其中舌片设置在一对相反的侧边缘中的一个侧边缘上,并且凹槽设置在同一对相反的侧边缘中的另一个侧边缘上。这种耦合装置的设计在本领域中是公知的,并且已经证明非常适合于用于浮动地板的面板。
另外,在根据本发明的面板中,优选的是互连耦合装置具有互锁特征,所述互锁特征避免互连面板的自由移动。
这种互锁特征可以是设置在相应的相反侧边缘上的凸起和相应的凹部,相邻的面板通过这些凸起和凹部彼此互锁。
当根据本发明的面板设置有互连耦合装置时,优选地,这些装置设置为支撑层整体的一部分。
这样,耦合装置由相对硬的材料制成,这有助于牢固的连接,这是耦合装置的坚固实施例,并且有助于在将装置耦合在一起方面对终端用户相对便利。
优选地,在根据本发明的面板中,芯层和/或支撑层是挤出的片材。这种层易于生产,并且挤出工艺适合于形成具有泡沫结构的片材—这是芯层的优选结构。
构成刚性顶层的各个层通过在高压下共同挤出或压延而层压形成。
本发明的一个特殊方面涉及一种由多个组装好的面板组成的防水地板或墙壁覆盖物,其中所述面板符合本发明的第一方面。这种覆盖物受益于上面已经阐述的相同优点。
在面板设置有互连耦合装置的情况下,通过将来自相应的相邻面板的互连耦合装置互连来组装面板。
在第二方面,本发明涉及一种生产根据本发明第一方面的面板的方法,包括以下步骤:
a)提供柔性的芯层,该芯层基本上由密度相对较低并且设有气穴形式的空隙的材料构成;
b)提供刚性的顶层,该顶层包括支撑层,该支撑层基本上由几乎没有气穴的密度相对较高的材料构成;
c)将刚性的顶层粘附到芯层的顶侧,优选通过在芯层和顶层的界面处施加粘合剂来进行。
所述方法的特征在于,芯层的厚度小于支撑层的厚度,优选地为0.5或更小的比率,更优选地为0.5至0.10之间的比率。
根据本发明的方法提供了一种新的、有利的方式来提供根据本发明的第一方面的面板。
与此一致,根据本发明第二方面的方法可以包括根据本发明第一方面的面板的任何优选特征。
对于根据本发明的面板,以下尺寸和特性是优选的:
-面板的总厚度:4.5mm至8.0mm;
-刚性顶层的厚度约为3.0mm;
-芯层的厚度约为1.0mm;
-背衬层的厚度约为1.0mm;
-面板的总宽度:120mm至600mm;
-面板的总长度:300mm至2500mm。
关于基于泡沫材料的芯层,以下特性是优选的:
孔径:0.01mm至0.5mm;
空隙容量:20%至50%;
密度:100kg/m3至300kg/m3。
附图说明
将参照附图进一步解释本发明,其中:
-图1以立体图示出了根据本发明的面板的优选实施例;
-图2示出了根据本发明的面板的优选实施例的横截面;
-图3示出了根据本发明的面板的几种变型的横截面;
-图4示出了相关现有技术中提出的面板的横截面。
具体实施方式
图1示出了面板1,其适于通过将多个所述面板彼此互连来组装防水地板或墙壁覆盖物,其中面板具有基本平坦的顶表面3和基本平坦的底表面5、以及至少四个基本线性的侧边缘6a、6b、6c、6d,包括至少一对相反的侧边缘6a、6c,侧边缘6a、6c设有用于将一个面板互连在另一个面板内的互连耦合装置7、8,该面板具有夹层结构,该夹层结构包括基本上由泡沫材料构成的芯层10、刚性的顶层12、以及背衬层14。
图2示出了与图1相同的实施例的横截面,其中互连耦合装置7、8包括舌片7和凹槽8,舌片7和凹槽8各自具有互锁特征20a(凸起)和20b(凹槽);当一个面板的舌片插入另一个相邻的面板的凹槽中时,避免了互连的面板的自由移动。
芯层10由基于EVA的泡沫结构组成,该泡沫结构具有柔软和柔韧的特性。芯层10的泡沫结构包含气穴形式的空隙,这些气穴由小圆圈10a示意性地描绘。
刚性的顶层12包括支撑层12a、装饰层12b、耐磨层12c和涂层12d。支撑层12a是刚性的高密度PVC材料,其不含增塑剂。
背衬层14由挤出的PVC材料构成,其不含增塑剂,因此是刚性的。
所示的厚度大致表示在本发明的面板中使用的实际厚度。所示面板的总厚度约为6mm。
图3示出了关于侧边缘6a和6c的设计方面,面板的几种变型。图3中的层的层压结构与图2中所示的层10、12和14的层压结构相同。
图3a示出了如图2所示的侧边缘6a和6c的设计,其允许通过倾斜进入运动将两个互补的侧边缘互锁;
图3b示出了侧边缘6a和6c的设计,其简单地是平坦表面,其中可以通过在相邻面板的接触的侧边缘上施加粘合剂材料而使侧边缘互锁;
图3c示出了侧边缘6a和6c的设计,其设有经典的凹槽8和舌片7设计,其需要水平转移运动以互连两个面板。
图3d示出了侧边缘6a和6c的设计,其设有另一个经典的凹槽8和舌片7设计,其允许通过竖直运动或下拉运动进行互连。
重要的是,在所示的所有上述舌片和凹槽设计中,两种类型的互连耦合装置都构成支撑层12a整体的一部分。
出于比较原因并结合下面给出的比较例,图4示出了相关现有技术中提出的面板的横截面。
比较例
将参考以下比较例进一步证实本发明的有益技术效果:
例I.
WPC地板产品(现有技术)
所谓的WPC地板面板是根据US9212494和所附的图4的公开内容生产的。
基本上,泡沫材料的芯层形成面板的主层,用于构成面板总厚度的一半以上(根据图4)。此外,舌片和凹槽轮廓是芯层整体的一部分。芯层的密度约为750kg/m3。
设置在泡沫材料的芯层上的顶层更致密,密度为1600kg/m3至1800kg/m3,高于芯层的密度值。
背衬层由EVA和PE垫层组成,密度约为200kg/m3。
例II.
根据本发明的面板
如图2所示的根据本发明的样品板生产为具有以下特性:
支撑层:
·由PVC制成,其几乎不含增塑剂并含有CaCO3作为填充材料,其中CaCO3以60wt.%的含量存在。
·厚度为2.5mm至3.0mm。
·密度为1800kg/m3至2000kg/m3。
·刚性、实心的特性。
芯层:
·由EVA、PE或PS泡沫制成。
·厚度为0.8mm至1.5mm。
·密度为100kg/m3至300kg/m3。
·柔软、柔韧的特性。
背衬层:
·由PVC制成,其几乎不含增塑剂并含有CaCO3作为填充材料,其中CaCO3以60wt.%的含量存在。
·厚度为0.8mm至2.0mm。
·密度至少为1600kg/m3。
·刚性、实心的特性。
共同特征:
面板I和II都在其顶表面上设有类似的精整层,即涂层、耐磨层和装饰层。使用的材料也是类似的,并且在本领域中通常使用。
对比测试:
两个面板都经过以下测试:
·声学测试;按照以下标准:
ISO 10140-1,ISO 717-2,ASTME2179-03,ASTME989-06。
·压痕测试;按照以下标准:
ASTM 1914。
·刚性测试;按照以下标准:
EN 310.
下表显示了通过上述测试获得的结果。
从上表中可以直接得出,根据本发明的面板不仅实现了足够的声学特性,而且在抗压痕性能和刚性方面也具有令人满意的值。
为了将所有这三种性能组合到适当的程度,本发明可以说是对现有技术的改进,相比之下,现有技术在抗压痕性能和刚性方面都显示出不足的值。
Claims (18)
1.一种面板,适于由多个所述面板组装防水地板或墙壁覆盖物,其中所述面板具有基本平坦的顶表面和基本平坦的底表面,所述面板具有多个层的层压结构,所述层包括:
-柔性的芯层,所述芯层基本上由设有气穴形式的空隙并且因此密度相对较低的材料构成,以及
-包括支撑层的刚性顶层,所述支撑层基本上由几乎没有气穴并且因此密度相对较高的材料构成,并且其中所述芯层的密度低于所述顶层的密度,
其特征在于,所述芯层的厚度小于所述支撑层的厚度,优选地为0.5或更小的比率,更优选地为0.5至0.10之间的比率。
2.根据权利要求1所述的面板,其中,所述支撑层直接或间接地设置在所述芯层的顶侧上。
3.根据前述权利要求中任一项所述的面板,其中,所述芯层的厚度范围为0.5mm至3.0mm,优选为0.8mm至1.5mm。
4.根据前述权利要求中任一项所述的面板,其中,所述支撑层的厚度范围为2.0mm至8.0mm,优选为2.5mm至4.0mm。
5.根据前述权利要求中任一项所述的面板,其中,所述芯层的密度为100kg/m3至300kg/m3。
6.根据前述权利要求中任一项所述的面板,其中,所述支撑层的密度为至少1200kg/m3,更优选为至少1400kg/m3,最优选为至少1600kg/m3。
7.根据前述权利要求中任一项所述的面板,其中,当根据EN310标准测量时,所述面板具有至少2000N/mm2的总体刚度。
8.根据前述权利要求中任一项所述的面板,其中,所述芯层的材料包括来自PE、EVA、PS、PP、PU或三聚氰胺的泡沫材料,或者软木。
9.根据前述权利要求中任一项所述的面板,其中,所述支撑层的材料包括热塑性材料,优选为PVC,更优选为几乎不含增塑剂并含有CaCO3作为填充材料的PVC,其中最优选地,CaCO3以60wt.%的含量存在。
10.根据前述权利要求中任一项所述的面板,其中,所述顶层包括耐磨层和在所述支撑层上方的装饰层,所述耐磨层可选地设有涂层。
11.根据前述权利要求中任一项所述的面板,其中,所述芯层的底侧直接或间接地设置有背衬层。
12.根据前述权利要求中任一项所述的面板,其中,所述面板具有至少四个基本上线性的侧边缘,所述侧边缘优选地具有矩形设计。
13.根据权利要求12所述的面板,其中,所述线性的侧边缘包括至少一对相反的侧边缘,所述相反的侧边缘设置有互连耦合装置,用于将一个面板互连在另一个面板内。
14.根据权利要求13所述的面板,其中,所述互连耦合装置包括舌片和凹槽,其中所述舌片设置在一对相反的侧边缘中的一个侧边缘上,并且所述凹槽设置在同一对相反的侧边缘中的另一个侧边缘上。
15.根据权利要求13或14所述的面板,其中,所述互连耦合装置设置为所述支撑层整体的一部分。
16.根据前述权利要求中任一项所述的面板,其中,所述芯层和/或所述支撑层是挤出的片材。
17.由多个组装好的面板组成的防水地板或墙壁覆盖物,其中,所述面板符合前述权利要求中任一项。
18.一种生产根据前述权利要求1至16中任一项所述的面板的方法,包括以下步骤:
a)提供柔性的芯层,所述芯层基本上由密度相对较低并且设有气穴形式的空隙的材料构成;
b)提供刚性的顶层,所述顶层包括支撑层,所述支撑层基本上由几乎没有气穴的密度相对较高的材料构成;
c)将刚性的所述顶层粘附到所述芯层的顶侧,优选通过在所述芯层和所述顶层的界面处施加粘合剂来进行,
其特征在于,所述芯层的厚度小于所述支撑层的厚度,优选地为0.5或更小的比率,更优选地为0.5至0.10之间的比率。
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CN (1) | CN110325362B (zh) |
AU (1) | AU2018228716B2 (zh) |
CA (1) | CA3054755A1 (zh) |
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Also Published As
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US11053695B2 (en) | 2021-07-06 |
CN110325362B (zh) | 2023-06-27 |
AU2018228716A1 (en) | 2019-09-19 |
NL2018440B1 (en) | 2018-09-19 |
WO2018158338A1 (en) | 2018-09-07 |
US20210285239A1 (en) | 2021-09-16 |
EP3589484A1 (en) | 2020-01-08 |
US11619053B2 (en) | 2023-04-04 |
AU2018228716B2 (en) | 2022-02-03 |
US20190383031A1 (en) | 2019-12-19 |
CA3054755A1 (en) | 2018-09-07 |
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