CN110770405A - 地板面板及其生产方法 - Google Patents

地板面板及其生产方法 Download PDF

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Publication number
CN110770405A
CN110770405A CN201880003808.1A CN201880003808A CN110770405A CN 110770405 A CN110770405 A CN 110770405A CN 201880003808 A CN201880003808 A CN 201880003808A CN 110770405 A CN110770405 A CN 110770405A
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CN
China
Prior art keywords
layer
floor panel
core layer
density
core
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Pending
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CN201880003808.1A
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English (en)
Inventor
托马斯·卢克·马丁·贝尔特
安东尼·德莱维特
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.)
CHINAFLOORS TIMBER (CHINA) Co.,Ltd.
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Champion United International
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Publication of CN110770405A publication Critical patent/CN110770405A/zh
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Abstract

本发明涉及一种地板面板，特别是氧化镁基地板面板，其优选地设置有互连耦合部件，所述互连耦合部件用于将相邻的地板面板彼此相互连接。本发明还涉及一种生产地板面板、特别是氧化镁基地板面板的方法。

Description

地板面板及其生产方法
技术领域
本发明涉及一种地板面板，特别是一种氧化镁基地板面板，其优选地设置有互连耦合部件，用于将相邻的地板面板彼此相互连接。本发明还涉及一种生产地板面板、特别是氧化镁基地板面板的方法。
背景技术
在地板和墙壁覆盖物领域中，基于木材或其衍生物的面板被广泛使用，特别是作为面板的主层或芯层的材料。在美国专利6,688,061中给出了一个示例。主要缺点是这种材料的吸湿性，吸湿性会影响这种面板的寿命和耐久性。作为替代方案，使用几种热塑性材料，例如聚氯乙烯；虽然它们是防水的，但存在其它缺点。用于诸如专利CN100419019中的面板的聚氯乙烯(PVC)具有柔性特性，其需要应用了面板覆盖物的基底的完全光滑和平整的表面。如果不是这种情况，那么任何不平整都将能够透过面板看到，因为面板与下面的基底表面是一致的，这从美学观点来看对用户是不利的影响。此外，在地板面板中使用PVC作为芯材导致地板面板易受其周围环境温度变化的影响，这将导致乙烯基地板在正常的冷热波动下膨胀和收缩。本领域普遍需要开发一种地板面板，该地板面板在具有防水性能的同时，还能够以相对统一的厚度制造，从而形成相对平整(平坦)的上表面。本领域还需要开发这样一种地板面板：其厚度可以在生产过程中相对容易地调节，同时保持面板的足够强度。还需要开发一种防火面板。
发明内容
本发明的目的是满足至少一个上述需求。
本发明的上述目的通过提供一种面板、特别是根据上述前序部分的地板面板来满足，该面板包括由以下层组成的层压体：氧化镁基芯层；位于所述芯层上方的至少一个氧化镁基上外壳层，其中所述上外壳层的密度优选大于芯层的密度；以及位于所述芯层和所述至少一个上外壳层之间的至少一个上增强层。与传统的木基和/或PVC基地板面板相比，氧化镁(MgO)作为地板面板材料的应用导致显著更低的可燃性，其中根据本发明的MgO基地板面板甚至可以完全防火(不易燃)。此外，MgO在芯层和外壳层中的应用使得地板也具有防水性。另外，在根据本发明的地板面板的芯层和外壳层中应用MgO导致地板面板不易受温度变化的影响，并且在环境温度波动期间尺寸稳定。根据本发明的地板面板的另一个重要优点是多个层的特定层压体的应用，其中相对高密度的上外壳层构造成经受砂磨处理(也称为喷砂处理，或者称为干式喷砂清理工艺)，目的是为了精确和均匀地减小所述外壳层的厚度，并因此减小地板面板的厚度。因此，在生产具有不同所需面板厚度(例如6mm、8mm和10mm)的地板面板期间，可以采用上述多层的(均匀的)层压体作为(均匀的)起点，之后将上外壳层砂磨至达到所需面板厚度的程度。至少一个上增强层的存在改善了面板的强度，并且允许对上外壳层进行砂磨。此外，上增强层还在面板的使用期间提供了额外的面板强度。相对低密度的芯层不如外壳层紧凑，因此重量相对较轻，这降低了地板面板的总重量。实验表明，如果每个外壳层的密度比芯层密度大8％至12％、特别是大约10％，则是特别有利的。芯层的密度优选在1000kg/m3至1800kg/m3之间，优选在1100kg/m3至1500kg/m3之间，更优选在1200kg/m3至1400kg/m3之间。上外壳层的密度优选在1100kg/m3至2000kg/m3之间，优选在1400kg/m3至1800kg/m3之间，更优选在1500kg/m3至1600kg/m3之间。主要地，本发明涉及地板面板，更具体地涉及用于形成地板覆盖物的装饰性地板面板，但不排除将根据本发明的面板与其他形式的覆盖物一起应用，例如作为墙板、天花板等。
根据本发明的地板面板可以是胶合地板面板。然而，地板面板、特别是芯层包括第一对相反的边缘，也是可以想象并且通常是有利的，其中所述第一对相反的边缘包括互补的耦合部件，所述耦合部件允许多个地板面板彼此相互耦合。这允许根据本发明的面板浮动地安装。更优选地，所述第一对边缘处的耦合部件形成第一锁定系统和第二锁定系统，第一锁定系统实现在由地板面板限定的平面中的垂直于相应边缘的锁定，第二锁定系统实现垂直于由地板面板限定的所述平面的锁定。这种在水平和竖直方向上的双重锁定效果改善了相邻地板面板的相互锁定。优选地，地板面板，特别是芯层，包括第二对相反的边缘，其中，两对相反的边缘都包括允许将多个地板面板彼此相互耦合的耦合部件。更优选地，第一对相反的边缘处的耦合部件构造成使得这些面板中的两个可以通过转动运动在这些边缘处彼此耦合，并且第二对相反的边缘处的耦合部件构造成使得这些面板中的两个可以通过一个面板相对于另一个面板的向下运动而彼此耦合，更具体地说，通过在第一对边缘处的转动运动而获得的向下运动来彼此耦合。在第二对边缘处的第二锁定系统可以包括一个接合在另一个后面的锁定部件，可以通过其弹性和/或可移动性而将这些锁定部件中的一个送至另一个后面。通过还将第二对侧边缘处的耦合部件集成到芯层中，通常获得了很大的性能，以实现允许通过向下运动来锁定的耦合。应当清楚的是，这些面板可以浮动地安装，但不排除根据替代方案，它们也可以胶合到下面的表面。
除了在芯层和上外壳层中存在氧化镁之外，优选地，芯层和/或上外壳层还包括硫酸镁和/或氯化镁。硫酸镁和氯化镁都用作粘结物(粘结剂)。在本发明的背景下，氧化镁和合适的粘合剂(例如硫酸镁和/或氯化镁)优选在总矿物材料中的组合含量为约60-90wt.％。此外，氧化镁和合适的粘结剂之间的重量比在4：1至2：1的范围内，优选为约3：1。由于与氯化镁相比，硫酸镁吸收的水少得多，因此通常优选使用硫酸镁作为(主要)粘结剂，这确保了在相对潮湿的环境中地板面板也具有足够的刚性。但是，这种优选并不排除在芯层中存在氯化镁。
在优选的实施例中，芯层和/或上外壳层包含木纤维。木纤维的存在通常改善了这些层的可加工性，这将因此有利于地板的生产。此外，在上外壳层中存在木纤维允许了装饰纸层耐久地胶合在所述上外壳层的上方。木材和纸都是基于纤维素的，允许彼此相对牢固和耐久的附着。为此，上外壳层包含至少10wt.％的木材，更优选40-50wt.％的木材是有利的。芯层中木纤维的重量含量优选大于上外壳层中木纤维的重量含量。这使得上外壳层与芯层的密度相比获得增加的密度，这有利于对上外壳层的砂磨。作为替代或补充，其他种类的天然纤维，特别是纤维素纤维，例如竹纤维或秸秆纤维，也可以应用在芯层和/或上外壳层中。
优选地，芯层和上外壳层均包含水，其中芯层中水的重量含量更优选大于上外壳层中水的重量含量。与芯层的密度相比，这使得有助于增加上外壳层的密度。这里，应注意氧化镁将与水反应，产生氢氧化镁(MgO+H2O→Mg(OH)2)。此外，如果使用的话，硫酸镁也可以通过水的存在而水合，主要产生七水硫酸镁。
至少一个上增强层的存在因此导致地板面板的显著改进，这在地板面板的生产(特别是砂磨)期间和使用期间都是有利的。此外，增强层通常导致瓷砖的声学(消音)性能的改善。增强层可以包括织造或非织造纤维材料，例如玻璃纤维材料。它们的厚度可以为0.2mm至0.4mm。优选地，上增强层包括玻璃纤维网。玻璃纤维网优选具有至少5×5mm的网眼尺寸，更优选(约)7×7mm。玻璃纤维网优选具有至少90g/m2的面积重量，从而为地板提供足够的强度。优选使用低碱性玻璃纤维网以确保长的持久强度。因为玻璃纤维的纤维在使用/(拆卸)安装地板面板期间可能导致人体皮肤瘙痒，所以玻璃纤维网优选地设有涂层。这使得纤维、特别是纤维末端对于人体皮肤而言不那么尖锐。这同样适用于使用玻璃纤维的单独(松散)纤维作为增强层的情况。合适的涂层例如是蜡、树脂或其他类型的涂层。
在一个优选的实施例中，根据本发明的地板面板的层压体还包括：位于芯层下面的至少一个氧化镁基下外壳层，其中所述至少一个下外壳层的密度优选大于芯层的密度；以及位于所述芯层和所述至少一个下外壳层之间的至少一个下增强层。至少一个下外壳层和位于下外壳层和芯层之间的至少一个下增强层的应用不仅使得根据本发明的地板面板具有额外的强度，而且还允许下外壳层被砂磨，因此在生产过程中厚度减少。这意味着在生产期间，可以在地板面板的顶表面和底表面上对地板面板进行砂磨(同时地和/或接连地)，这使得能够控制上外壳层的厚度、下外壳层的厚度，并因此控制面板厚度。层压体包括彼此堆叠的多个下增强层、优选两个下增强层是有利的。两个(或更多个)下增强层的应用通常显著改善了面板强度。这里，层压体包括多个下外壳层通常是有利的，其中至少一个下外壳层位于至少两个下增强层之间，并且其中至少一个下外壳层位于最低的下增强层的下方。由两个下增强层包围的中间下外壳层的厚度通常很小，通常约为1mm或更小。下外壳层的密度优选在1100kg/m3至2000kg/m3之间，优选在1400kg/m3至1800kg/m3之间，更优选在1500kg/m3至1600kg/m3之间。下外壳层的组成可以与上外壳层的组成相同，不同之处在于下外壳层可以不含木纤维。这改善了下外壳层的(所需)刚性。与上增强层相比，下增强层可以具有相同的组成，并且优选地(也)由可选地至少部分涂覆的玻璃纤维网形成。背衬层可以应用到(最低的)下外壳层的下侧。可以想象的是，在层压体包含：(i)位于芯层下面的至少一个氧化镁基下外壳层，其中所述至少一个下外壳层的密度优选大于芯层的密度；以及(ii)位于所述芯层和所述至少一个下外壳层之间的至少一个下增强层—的情况下，可以省略上外壳层，并且可选地，也可以省略上增强层。
在上外壳层的上方，优选地通过胶合而通常附着有顶部结构，其中所述顶部结构包括装饰层和覆盖所述装饰层的耐磨层。装饰层由设有和/或印有图案的薄膜组成。装饰层可以是纸层和/或聚合物层，例如PVC层。耐磨层通常基本上是透明的。耐磨层可以由一个或多个透明漆层组成。耐磨层可以由乙烯基(PVC)薄层构成，其中结合有耐磨颗粒，优选陶瓷颗粒，例如刚玉等。代替应用聚合物装饰层，层压体还可以包括脲-甲醛(树脂)浸渍的装饰纸层，其附着于上外壳层，优选为胶合。后一实施例的优点在于，脲-甲醛也起到相对耐刮擦的耐磨层的作用。此外，纸层可以相对牢固且耐久地胶合至上外壳层，特别是在上外壳层设有如上所述的木纤维的情况下。通常，本发明的面板中顶部结构的厚度在0.2mm至2.0mm的范围内。
本发明还涉及一种生产根据前述权利要求中任一项所述的地板面板的方法，包括以下步骤：
A)提供层压体，该层压体具有：
○氧化镁基芯层；
○位于所述芯层上方的至少一个氧化镁基上外壳层，其中所述上外壳层的密度大于芯层的密度；和
○位于所述芯层和所述至少一个上外壳层之间的至少一个上增强层；以及
B)通过对所述上外壳层进行砂磨处理来减小至少一个上外壳层的厚度。
在根据步骤B)的砂磨处理期间，物理地去除(蚀刻/用砂喷走)材料。通过使用现有的喷砂设备可以非常精确地实现材料的去除，这既可以精确控制上外壳层的厚度，并因此精确控制面板的厚度，又可以获得上外壳层的相对统一的厚度，并因此获得面板的平整(平坦)的上表面。在步骤B)期间，优选使用带有砂带的砂光机。为了获得更好的效果，建议首先使用侵蚀性(砂)纸、例如典型砂粒尺寸为80的(砂)纸进行砂磨。根据外壳层的粗糙度，可能需要用同一(砂)纸重复该砂磨步骤多次，最好是2或3次。随后，可以用至少一个具有更细砂粒的(砂)纸对外壳层进行砂磨。这里，可以想象，例如用砂粒尺寸为120的砂纸砂磨一次，然后用砂粒尺寸为240的砂纸砂磨外壳层。可以想象，在步骤A)中使用的层压体另外包括：
-位于芯层下面的至少一个氧化镁基下外壳层，其中所述至少一个下外壳层的密度大于芯层的密度；以及
-位于所述芯层和所述至少一个下外壳层之间的至少一个下增强层；
所述方法还包括步骤C)，步骤C)包括通过对所述上外壳层进行砂磨处理来减小至少一个下外壳层的厚度。优选地，该方法包括在步骤B)之后的步骤D)，其中步骤D)包括将装饰层、优选为脲-甲醛浸渍的装饰纸层附着到砂磨过的上外壳层上。以上已经以综合方式阐释了优点和替代实施例。
本发明还涉及一种覆盖物，特别是地板覆盖物，其包括多个互连的根据前述权利要求中任一项所述的面板。
附图说明
将基于以下附图中所示的非限制性的示例性实施例来阐明本发明。这里：
图1以俯视图示出了根据本发明的面板，更具体地说是地板面板；
图2和图3以更大的比例表示根据图1中的线II-II的横截面；
图4和图5表示面板能够如何在其长边处相互连接；
图6和图7表示面板如何在其短边处相互配合；
图8表示图1中的多个面板如何能够相互连接；
图9以较大的比例表示图8中的F9所示的部分；
图10表示根据本发明的替代地板面板的详细侧视图。
图11a-11c表示用于制造图10中所示的面板的接连的工艺步骤。
图12表示根据本发明的又一个地板面板的详细侧视图。
具体实施方式
在图1至图7中所示的示例中，面板1制成长方形条带，因此包括：第一对相反的边缘2和3，边缘2和3在这种情况下构成面板1的长边；以及第二对相反的边缘4和5，边缘4和5构成面板1的短边。通常，地板面板1的宽度在100mm至600mm的范围内，长度在300mm至2500mm的范围内。如图2和图3中更详细表示地，两对相反的边缘2和3以及4和5分别包括耦合部件6和7、8和9，这些耦合部件允许多个这样的面板1彼此相互耦合。如图4和图5中具体表示的那样，第一对相反的边缘2和3处的耦合部件6和7构造成使得两个这样的面板可以通过转动运动以锁定方式在这些边缘2和3处彼此耦合。这里，耦合部件6和7形成第一锁定系统和第二锁定系统，其中第一锁定系统实现在面板1的平面中并且垂直于所述边缘2和3的锁定，因此在这种情况下是在水平方向上的锁定，第二锁定系统实现垂直于面板1的平面的锁定，因此在这种情况下是在竖直方向上的锁定。为此目的，耦合部件6和7构造为舌片10和凹槽11，其提供竖直锁定并且包括锁定部件12和13，锁定部件12和13在耦合状态下防止舌片和沟槽的分离。这里，如图所示，优选地，凹槽11由下唇缘14和上唇缘15限制，并且锁定部件12和13以协作的突起的形式分别在舌片10的下侧和下唇缘14的上侧处实现。通过为此目的而设置的锁定表面16和17进行这种协作。还如图所示，还优选的是，下唇缘14侧向地延伸，直到超出上唇缘15的远端，更具体地，使得锁定表面17完全位于下唇缘14的超出上唇缘15的部分中。如图6和图7中示意性地表示的那样，第二对相反的边缘4和5处的耦合部件8和9构造成使得两个这样的面板1可以通过一个面板相对于另一个面板的向下运动而彼此耦合。这种向下运动将在下面更详细地讨论。如图7中清楚可见，这里的耦合部件8和9也形成第一锁定系统和第二锁定系统，其中第一锁定系统实现在面板1的平面中并且垂直于所述边缘4和5的锁定，因此在这种情况下是在水平方向上的锁定，第二锁定系统实现垂直于面板1所限定的平面的锁定，因此在这种情况下是在竖直方向上的锁定。第一锁定系统基本上由位于边缘5处的向上指向的下钩形部分18以及位于相反的边缘4处的向下指向的上钩形部分19形成，这些钩形部分通过所述向下运动一个在另一个后面地接合。下钩形部分18包括唇缘20，唇缘20从面板1的下边缘侧向地延伸并且设置有向上指向的锁定元件21，锁定元件21具有锁定表面22，而上钩形部分19包括唇缘23，唇缘23从面板1的上边缘侧向地延伸并且设置有向下指向的锁定元件24，锁定元件24具有锁定表面25。短边处的边缘的第二锁定系统由锁定部件26和27形成，锁定部件26和27分别位于下钩形部分18的近端28和上钩形部分19的远端29的旁边。锁定部件26和27包括一个在另一个后面接合的突起，突起限定了锁定表面30和31。应注意，耦合部件8和9主要也可以被认为是舌片和凹槽耦合，其中锁定部件27用作舌片，而该舌片所坐落其中的凹槽由用作上唇缘的锁定部件26和用作下唇缘的第一钩形部分18限定。应注意，竖直主动锁定部件26和水平主动锁定元件21之间的空间(也由开口H表示)用作阴部件32，而锁定元件24制成为阳部件33，阳部件33配合到阴部件32中。面板1基本上是基于氧化镁(MgO)形成的。更具体地，它包括芯层(基底)，芯层基于氧化镁实现，通常富含至少一种粘结剂，例如硫酸镁和/或氯化镁。芯层由图2至图7中的附图标记34表示。在这些图中，该基底示意性地描绘为单层。在实际中，这可以是单层以及多层，其并非都必须包含氧化镁。通常，顶层35设置在芯层34上，顶层35在图2至图7中也由单层表示，但在实际中，顶层35也可以由多个层组成，通常至少是由至少一个耐磨层覆盖的装饰层。顶层35的目的至少是在面板1处提供装饰性上侧36，优选为印刷装饰的形式，并且至少在地板面板的情况下，顶层35的目的是提供耐磨表面。如图7中所示，面板具有总厚度T。厚度T优选地具有介于3mm和10mm之间的值。特别是在实际的实施例中，该值将介于4mm和7mm之间。
在图8和图9中，示意性地表示了如何安装面板1。为了解释该方法，为了另外区分，多个面板1由附图标记1A、1B、1C表示。面板1一排一排地铺设并且相互耦合。为了实现面板在边缘2和3以及4和5处的耦合，该方法至少包括以下步骤：安装用于形成第一排面板的一部分的第一面板1A；例如在第一边缘2和3处将第二面板1B耦合到所述第一面板1A，其中该第二面板1B用于形成与所述第一排面板接续的第二排面板的一部分；在第二排中将第三面板1C耦合到所述第二面板1B以及第一面板1A两者，其中第三面板1C通过转动运动耦合到第一面板1A，其中第三面板1C从向上枢转位置被带入与第一面板和第二面板基本相同的平面，而由于这种运动和在其中产生的向下运动，钩形部分18和19在第三面板和第二面板之间彼此接合。显然，通常在安装第一面板1A和将第二面板1B耦合至第一面板1A之间，首先还要安装第一面板1A所在的排的所有其他面板。将第二面板1B耦合到第一面板1A也通过借助于如图4所示的转动运动在其边缘2处将面板1B连接至第一面板1A的边缘3和面板1A的排的其他可能的面板来执行。当将面板1C连接到面板1A时，也应用如图4所示的转动运动。这里，在短边缘4和5处执行向下运动M，耦合部件8和9通过该向下运动M彼此接合。通过该向下运动M，在非常广泛的意义上，涵盖每种形式的如下运动：其中在如图6和图7所示的横截面中，一个面板相对于另一个面板从较高位置放下。该运动M不一定必须是直线运动，并且在该运动期间，可能发生在面板中、更具体是在钩形部分18和19中的暂时变形。理论上，在横截面中看是直线的或几乎直线的向下运动M可用于将面板1C接合到面板1B中，这意味着从横截面看的图6中的右手侧面板被简单地径直下压到图7的位置。很明显，在此将有效地发生小的局部变形，因为锁定部件26和27必须通过卡扣效应一个接一个地按压复位。在此，通过芯层34的氧化镁基材料的(一定的)弹性和组成部件中的弯曲作用以及由此产生的材料中的压缩来获得卡扣效应。
图10示出了根据本发明的替代地板面板40的详细侧视图，但是其可以是与图1至图9中所示相同的地板面板1。地板面板40包括彼此堆叠的多个层的层压体，其中所述层压体从下向上包括以下层：
-背衬层41；
-下外壳层42；
-两个下玻璃纤维网43a、43b；
-芯层44；
-上玻璃纤维网45；
-上外壳层46；以及
-顶层47和/或顶部结构47。
背衬层41可以由纸、特别是树脂浸渍纸构成。这里，优选使用三聚氰胺树脂浸渍纸。背衬层41有助于在面板和应用了面板的下面的表面之间提供最佳界面。与芯层44的密度相比，外壳层42、46具有更高的密度，这为地板面板40提供了刚性。此外，这与用作增强层的玻璃纤维网43a、43b、45相结合允许在生产过程中对外壳层42、46进行砂磨(喷砂)。外壳层42、46和芯层44包括氧化镁、粘结剂例如氯化镁和/或硫酸镁、以及添加剂。下面给出三层的典型组成。
顶层47可以由一层或多层组成，并且可以包括脲-醛树脂浸渍的装饰纸层，装饰纸层优选通过一种或多种胶水附着到上外壳层46上。如图10所示，地板面板40的一对相反的侧边缘设有互补的耦合部件，特别是阳耦合部件48和互补的阴耦合部件49，以允许面板相互连接，如上面详细讨论的。地板面板40的其余边缘(未示出)可设置有相同和/或替代形状的一组耦合部件。具有舌片形状的阳耦合部件48由芯材构成，并且还包括上玻璃纤维网45。可选地，上外壳层46的变薄(砂磨)部分也可以包括在阳耦合部件40中。阴耦合部件49构成凹槽，该凹槽构造成容纳相邻地板的互补舌片。所述凹槽由上唇缘49a和下唇缘49b包围，其中上唇缘49a由上外壳层46和顶层47形成，下唇缘49b由芯层44、两个下玻璃纤维网43a、43b以及背衬层41形成。凹槽的下部形成在芯层44内，与下玻璃纤维网43a、43b相距一定距离。下玻璃纤维网43a、43b之间的距离可以是零，但是也可以想到将网43a、43b彼此相距一定距离定位，其中下外壳层42的材料位于两个网43a、43b之间。
在图11a-11c中示出了如图10所示的制造地板面板40的接连的方法步骤。在图11a中，示出了具有原始相对较厚的上外壳层46的起始层压体。通常，该上外壳层46作为浆料(糊料)应用在位于芯层44上方的上玻璃纤维网45的上方。通过已知的高精度喷砂设备50，减小了上外壳层46的厚度，这是通过从所述上外壳层46去除材料直到达到所需的面板厚度来完成的(图11b)。随后，如图11c所示，顶层47被应用，优选地胶合在上外壳层46的上方，产生如图10所示的最终地板面板40。可选地，还可以对下外壳层42进行砂磨处理(在应用背衬层41之前)，这提供了基于(均匀的、通常尺寸过大的)起始层压体调节面板厚度的更大的灵活性和自由度。
图12示出了根据本发明的又一个地板面板51的详细侧视图，但其(也)可以是与图1至图9中所示相同的地板面板1。地板面板51包括彼此堆叠的多个层的层压体，其中所述层压体从下向上包括以下层：
-第一下外壳层52；
-第一下玻璃纤维网53；
-第二下外壳层54；
-第二下玻璃纤维网55；
-芯层56；
-上玻璃纤维网57；
-上外壳层58；
-PVC子层59；以及
-PVC顶层60或顶部结构60。
在该实施例中，PVC顶层60由PVC装饰层构成，所述PVC装饰层被PVC耐磨层覆盖。PVC子层59优选不含任何增塑剂。子层59位于芯层56和顶层60之间，以达到所需的效果，例如声音改善、抗压痕性能改善。其他层52-58的组成可以与图10所示的等效层相同。两个下网53、55之间的距离约为1mm。如图12所示，地板面板51的一对相反的侧边缘设有互补的耦合部件，特别是阳耦合部件61和互补的阴耦合部件62，从而允许面板相互连接，如前面所广泛论述的。地板面板51的其余边缘(未示出)可以设置有相同和/或替代形状的一组耦合部件。具有舌片形状的阳耦合部件61由芯层56、上玻璃纤维网57和上外壳层58组成。阴耦合部件62构成凹槽，该凹槽构造成容纳相邻地板的互补的舌片。所述凹槽被上唇缘62a和下唇缘62b包围，其中上唇缘62a由上外壳层PVC子层59和顶层60形成，下唇缘62b由芯层56、两个下玻璃纤维网53和55、以及第一和第二下外壳层52、54形成。凹槽的下部形成在芯层44内，与下玻璃纤维网43a、43b相距一定距离以确保阴耦合部件62的足够的刚度和强度。图12所示的地板面板51是防水、防火和刚性的。
显而易见的是，本发明不限于本文所示和所述的工作实例，而是在所附权利要求的范围内可以有许多变型，这些变型对于本领域技术人员来说是显而易见的。
通过若干说明性实施例说明了上述发明构思。可以想到的是，可以应用各个发明构思，而在这样做时不需要还应用所描述的示例的其他细节。没有必要详细说明上述发明构思的所有可想到的组合的示例，因为本领域技术人员将理解，可以(重新)组合许多发明构思以便达到特定应用。
本专利公开中使用的动词“包括”及其变体应理解为不仅意味着“包括”，而且还应理解为意指短语“包含”、“基本上由……组成”，“由……形成”及其变体。

Claims (37)

1.一种地板面板，包括层压体，所述层压体包括：
-氧化镁基芯层；
-位于所述芯层上方的至少一个氧化镁基上外壳层，其中所述上外壳层的密度大于所述芯层的密度；以及
-位于所述芯层和所述至少一个上外壳层之间的至少一个上增强层。
2.根据权利要求1所述的地板面板，其中，所述地板面板、特别是所述芯层包括第一对相反的边缘，所述第一对相反的边缘包括互补的耦合部件，所述耦合部件允许多个地板面板彼此相互耦合。
3.根据权利要求2所述的地板面板，其中，所述第一对边缘处的耦合部件形成第一锁定系统和第二锁定系统，所述第一锁定系统实现在由所述地板面板限定的平面中的垂直于相应边缘的锁定，所述第二锁定系统实现垂直于由地板面板限定的所述平面的锁定。
4.根据权利要求2或3所述的地板面板，其中，所述地板面板、特别是所述芯层包括第二对相反的边缘，两对相反的边缘都包括允许多个地板面板彼此相互耦合的耦合部件。
5.根据前述权利要求中任一项所述的地板面板，其中，所述芯层包括硫酸镁和/或氯化镁。
6.根据前述权利要求中任一项所述的地板面板，其中，所述上外壳层包括硫酸镁和/或氯化镁。
7.根据前述权利要求中任一项所述的地板面板，其中，所述芯层包括木纤维。
8.根据前述权利要求中任一项所述的地板面板，其中，所述上外壳层包括木纤维。
9.根据权利要求7和8所述的地板面板，其中，所述芯层中木纤维的重量含量大于所述上外壳层中木纤维的重量含量。
10.根据前述权利要求中任一项所述的地板面板，其中，所述芯层和所述上外壳层均包含水，并且其中所述芯层中水的重量含量大于所述上外壳层中水的重量含量。
11.根据前述权利要求中任一项所述的地板面板，其中，所述上增强层包括玻璃纤维。
12.根据前述权利要求中任一项所述的地板面板，其中，所述上增强层包括玻璃纤维网。
13.根据前述权利要求中任一项所述的地板面板，其中，所述玻璃纤维网具有至少5×5mm的网眼尺寸。
14.根据权利要求12或13所述的地板面板，其中，所述玻璃纤维网具有至少90g/m2的面积重量。
15.根据前述权利要求中任一项所述的地板面板，其中，所述玻璃纤维网设有涂层。
16.根据前述权利要求中任一项所述的地板面板，其中，所述芯层的密度在1000kg/m3至1800kg/m3之间，优选在1100kg/m3至1500kg/m3之间，更优选在1200kg/m3至1400kg/m3之间。
17.根据前述权利要求中任一项所述的地板面板，其中，所述上外壳层的密度在1100kg/m3至2000kg/m3之间，优选在1400kg/m3至1800kg/m3之间，更优选在1500kg/m3至1600kg/m3之间。
18.根据前述权利要求中任一项所述的地板面板，其中，所述层压体还包括：
-位于所述芯层下面的至少一个氧化镁基下外壳层，其中所述至少一个下外壳层的密度大于所述芯层的密度；以及
-位于所述芯层和所述至少一个下外壳层之间的至少一个下增强层。
19.根据权利要求18所述的地板面板，其中，所述层压体包括彼此堆叠的多个下增强层。
20.根据权利要求19所述的地板面板，其中，所述层压体包括多个下外壳层，其中至少一个下外壳层位于至少两个下增强层之间，并且其中至少一个下外壳层位于最低的下增强层的下方。
21.根据权利要求18至20中任一项所述的地板面板，其中，所述下外壳层的密度在1100kg/m3至2000kg/m3之间，优选在1400kg/m3至1800kg/m3之间，更优选在1500kg/m3至1600kg/m3之间。
22.根据权利要求18至21中任一项所述的地板面板，其中，所述下外壳层包括硫酸镁和/或氯化镁。
23.根据权利要求18至22中任一项所述的地板面板，其中，所述下外壳层不含木纤维。
24.根据前述权利要求中任一项所述的地板面板，其中，所述芯层和所述下外壳层均包含水，并且其中所述芯层中水的重量含量大于所述下外壳层中水的重量含量。
25.根据权利要求18至24中任一项所述的地板面板，其中，所述下增强层包括玻璃纤维。
26.根据权利要求25所述的地板面板，其中，所述下增强层包括玻璃纤维网。
27.根据权利要求26所述的地板面板，其中，所述玻璃纤维网具有至少5×5mm的网眼尺寸。
28.根据权利要求26或27所述的地板面板，其中，所述玻璃纤维网具有至少90g/m2的面积重量。
29.根据权利要求26至28中任一项所述的地板面板，其中，所述玻璃纤维网设有涂层。
30.根据权利要求18至29中任一项所述的地板面板，其中，至少一个下外壳层的下表面被砂磨。
31.根据前述权利要求中任一项所述的地板面板，其中，至少一个上外壳层的上表面被砂磨。
32.根据前述权利要求中任一项所述的地板面板，其中，所述层压体包括顶部结构，所述顶部结构附着至所述上外壳层，优选胶合至所述上外壳层，其中所述顶部结构包括装饰层和覆盖所述装饰层的耐磨层。
33.根据前述权利要求中任一项所述的地板面板，其中，所述层压体包括脲-甲醛浸渍的装饰纸层，所述装饰纸层附着于所述上外壳层，优选为胶合。
34.根据前述权利要求中任一项所述的地板面板，其中，每个外壳层的密度比所述芯层的密度大8％至12％，特别是大约10％。
35.一种生产根据前述权利要求中任一项所述的地板面板的方法，包括以下步骤：
A)提供层压体，所述层压体具有：
ο氧化镁基芯层；
ο位于所述芯层上方的至少一个氧化镁基上外壳层，其中所述上外壳层的密度大于所述芯层的密度；和
ο位于所述芯层和所述至少一个上外壳层之间的至少一个上增强层；以及
B)通过对所述上外壳层进行砂磨处理来减小至少一个上外壳层的厚度。
36.根据权利要求35所述的方法，其中，在步骤A)中提供层压体，所述层压体另外包括：
-位于所述芯层下面的至少一个氧化镁基下外壳层，其中所述至少一个下外壳层的密度大于所述芯层的密度；以及
-位于所述芯层和所述至少一个下外壳层之间的至少一个下增强层；
其中所述方法还包括步骤C)，步骤C)包括通过对所述上外壳层进行砂磨处理来减小至少一个下外壳层的厚度。
37.根据权利要求35或36所述的方法，其中，所述方法包括在步骤B)之后的步骤D)，其中步骤D)包括将装饰层、优选为脲-甲醛浸渍的装饰纸层附着到砂磨过的上外壳层上。
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