CN112236309A - 具有石料砌面的面板 - Google Patents

具有石料砌面的面板 Download PDF

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CN112236309A
CN112236309A CN201880094370.2A CN201880094370A CN112236309A CN 112236309 A CN112236309 A CN 112236309A CN 201880094370 A CN201880094370 A CN 201880094370A CN 112236309 A CN112236309 A CN 112236309A
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panel
carrier plate
layer
water glass
adhesive
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迪特尔·多林
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Zairo Technologies AG
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Zairo Technologies AG
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Abstract

本发明涉及一种面板(20)和一种用于制造这种面板的方法，该面板特别是墙壁、天花板或地板面板，该面板包括具有前表面和后表面的承载板(10)。承载板(10)是具有3至30mm的厚度的矿棉板或纤维水泥板，并且在其前表面上包括由石料砌面制成的层(26)。

Description

具有石料砌面的面板
技术领域
本发明涉及一种面板以及用于生产这种面板的方法，该面板特别是壁、顶板或地板面板，该面板设置有石料砌面。
背景技术
从现有技术中，已知许多用于墙壁、天花板或地板的面板。例如，作为室内使用的地板部件，所谓的层压面板是公知的。层压面板相对便宜并且易于加工。通常，它们是基于MDF或HDF的承载板，由此将浸有三聚氰胺树脂的装饰纸施加到其前表面上。通过在施加热量和压力下进行挤压，使树脂固化，从而产生高度耐磨的表面。为了增加阻力，在挤压面板之前，前表面通常设置有耐磨颗粒、特别是刚玉。这种层压面板的一个缺点是，它们很难适合于在建筑物的外侧应用，在外侧它们可能会受到湿气和环境的影响。
此外，根据现有技术，基于PVC的高质量面板是已知的，其以表述LVT(豪华乙烯瓷砖)在市场上销售。例如，从DE 10 2006 058 655A1中已知一种多层矩形层压形式的地板面板，其具有由软质聚氯乙烯(PVC)制成的承载板。将装饰纸分别胶合到软质PVC层和板上，以为PVC的可见表面提供装饰。
所有这些解决方案的共同点是，装饰层是例如印刷到纸或塑料网上的人造装饰。目的是对自然表面、特别是木制表面的特殊复制。相应的装饰纸和装饰箔能够分别可用于大量不同的自然表面(如木材、石料、瓷砖等)仿制品。
虽然现代印刷技术能够产生非常好的印刷质量，但是在许多情况下仍然不希望使用天然材料的仿制品，而是希望使用天然材料本身。
然而，例如木材、石料或瓷砖等天然材料的使用和加工相对复杂，并且材料相对昂贵，这是层压面板首先发展的主要原因之一。此外，例如天然石料在处理材料时包括另外的缺点，因为石料不是非常柔性的并且材料本身非常重。例如，在大面积应用需要天然石料或希望将重量保持在最低限度的区域，例如当建筑物的覆层立面时，天然石料的砌面材料已被证明是合适的。天然石料的砌面由胶合到柔性承载材料上的非常薄的(例如0.5至2mm之间)石料层组成。这样，砌面易于处理，并且可以例如以面板的形式用作壁覆盖物，特别是在建筑物的内侧。然而，已知的石料砌面的一个缺点是阻力、特别是机械阻力相对较低。因此，这些材料几乎不适合作为例如用于地板的材料。
根据已知的面板和覆盖物，本发明的目的是提供一种面板，特别是墙壁、天花板或地板面板，其优选地包括已知面板的优点，同时消除了现有技术的所述缺点。特别地，本发明的目的是提供一种具有石料砌面的改进面板，其提供了良好的阻力并且相对容易安装。
将在以下描述中提及的或本领域技术人员将认识到的这些任务和其他任务通过根据权利要求1的面板和根据权利要求15的用于制造这种面板的相应方法来解决。
发明内容
该目的特别是通过一种例如墙壁、天花板或地板面板的面板来解决，该面板包括具有前表面和后表面的承载板，由此承载板是具有优选地3至30mm的厚度的矿棉板或纤维水泥板，并且由此，承载板在其前表面上包括粘合剂的第一层以及石料砌面的第二层，第二层具有0.1至4mm的厚度，并且通过所述粘合剂胶合到承载板。
矿棉是对通过例如纺丝或拉伸熔融矿物形成的纤维材料的通用术语。矿棉又称为矿物纤维、矿物棉、人造矿物纤维、玻璃棉等。它通常用作建筑物隔热或吸音或防火目的的隔绝体。为了用作承载板，矿棉必须具有足够的稳定性。为此，将绒线致密化，使得其具有例如20至200kg/m3的密度。纤维水泥板是复合建筑和构筑材料。它们基本上由水泥和纤维增强物的复合物组成，例如玻璃纤维或纤维素纤维。纤维水泥由于其低成本、低重量并且易于加工而非常适合作为用于面板的承载板的材料。例如3至30mm的厚度提供了足够的机械稳定性，使得面板易于处理并且能够例如容易地安装。石料砌面层通过粘合剂胶合到承载板的前表面上。粘合剂首先用于将砌面固定到承载板上，另一方面，其优选地提供一定的弹性，由此更好地保护石料砌面免受压缩载荷，压缩载荷例如时发生在面板用作地板面板时。粘合剂层缓冲机械冲击并且将其传递到承载板中。为此，优选地将粘合剂层连续设置在承载板上。然而，粘合剂层也可以通过几个粘合剂带或粘合剂点来提供，使得在施加石料砌面之后，在粘合剂之间保留间隙。因此，承载板的前表面不必被粘合剂连续覆盖，而是也可以仅覆盖表面的一部分，只要粘合强度足够即可。
优选地，可以在粘合剂层与由石料砌面制成的层之间设置附加层。特别地，使用底漆可以改进石料砌面、粘合剂与承载板的表面的粘合。附加的功能层、特别是弹性层也是可行的。
优选地，粘合剂是高弹性聚氨酯粘合剂。
进一步优选地，粘合剂层以50μm至3mm、甚至更优选为200μm至2.5mm、还更优选为300μm至2mm、最优选为500μm至2mm的厚度施加。粘合剂的厚度应当充分选择，使得优选地，石料砌面的整个表面经由粘合剂层与承载板结合。由于天然石料砌面通常不具有光滑表面，而是根据石料而包括隆起和凹陷，因此优选的是，粘合剂施加为使得其能够平整/均匀这些不规则性。当稍后将如此制备的板切割成面板形状时以及当随后为面板设置锁定轮廓时，石料砌面的完全且连续的粘合是特别有利的。为此，在设置锁定轮廓的区域中，优选地在石料砌面与承载板之间应当存在连续的结合。为了更好地理解，这在图3中示意性地示出。因此，在最终产品中，粘合剂层将具有适应于砌面层的隆起和凹陷的不规则或不均匀的厚度。
通常优选的是，粘合剂层在最终产品中也具有50μm至3mm、更优选为200μm至2.5mm、甚至更优选为300μm至2mm、最优选为500μm至2mm的厚度(固化之后，尽管固化引起的收缩通常可以忽略)。因此，本领域技术人员将选择所施加的层的厚度，使得在最终产品中，可以实现期望的厚度。相对厚的粘合剂层还在承载板与施加在其上的石料砌面层之间提供一定的弹性阻尼。特别地，当用作地板面板时，粘合剂层的所述厚度是有利的，因为粘合剂层用作脚步隔音层，并且由于其弹性性质，其可以抑制作用在石料砌面层上的机械冲击以防止砌面破裂。
优选地，粘合剂的设置量为50至5000g/m2、更优选为70至4000g/m2、甚至更优选为300至3000g/m2、最优选为500至2500g/m2。通过这些量，可以实现石料砌面的安全粘合，并且所得粘合剂层分别具有足够的厚度和强度以实现上述优点。粘合剂的优选密度在1000至1700kg/m3之间、更优选在1200至1500kg/m3之间。
优选地，粘合剂层的肖氏A硬度(DIN EN ISO 868)为25至95、更优选为27至80、最优选为30至70。断裂伸长率(根据EN ISO 527-1)，也称为失效应变，优选为100至600％、更优选为150至500％、最优选为200至400％。这种断裂伸长率是有利的，因为粘合剂层具有足够的弹性，以在用作地板面板时提供良好的脚步隔音，并且抑制对石料砌面层的任何机械冲击。因此，分别增加了由此形成的面板的石料砌面的阻力。
承载板具有优选为3至20mm、更优选为4至15mm、甚至更优选为3至12mm、最优选为4至10mm的厚度。这些厚度是足够的，使得可以将例如榫舌和凹槽元件形式的耦接装置机加工到承载板的侧部中，并且使得承载板具有足够的稳定性，使得面板可以例如用作地板面板。同时，承载板仍然足够薄，使得只需要相对少的材料，并且最终的面板不会太重，使得其可以很容易地处理和安装。
通常优选地，矿棉承载板具有20至180kg/m3、更优选为30至160kg/m3、甚至更优选为40至150kg/m3、最优选为60至130kg/m3的密度。这种密度为承载板提供了足够的机械稳定性。
优选地，矿棉的承载板包括改性表面，该改性表面可以通过用水和水玻璃(特别是硅酸钠)的水溶液处理承载板来实现。本文使用的术语“水玻璃”(有时也称为“可溶性玻璃”)描述硅酸钠、硅酸钾和硅酸锂。用水玻璃、特别是硅酸钠处理惊人地导致承载板的耐湿性提高。对承载板的处理优选通过水玻璃的水溶液来进行。例如，可以用硅酸钠的水溶液喷射承载板，或者可以将其浸入这样的溶液中。在处理承载板之后，优选干燥该承载板，随后施加石料砌面层。优选地，水溶液由以下混合(重量份)：1份水玻璃和1至10份水、优选为1份水玻璃(例如硅酸钠)和1.5至7份水、最优选为1份水玻璃和1.5至3份水。水玻璃(例如硅酸钠)优选在高压下制备，例如在4至5巴下，并且相应地升高温度例如130至150℃，因为在这些范围内，固体水玻璃可以容易地溶解在水中。水溶液可以另外用碱性溶液和另外的水来处理以获得所需的成分。
优选地，承载板用水溶液喷射或浸入水溶液中。此时，水溶液优选地仍具有优选高于60℃的升高温度，因为尤其是水溶液的粘度是温度的函数。通常优选的是，用水溶液处理承载板因此在50至80℃、优选为60至70℃、甚至更优选为60至68℃的溶液温度下进行。
在一种用于制造面板、特别是墙壁、天花板或地板面板的方法中，优选地进行以下步骤：
a.提供具有前表面和后表面的矿棉的承载板；
b.用水玻璃(特别是硅酸钠)处理承载板；
c.通过粘合剂层将石料砌面层胶合到前表面上，石料砌面层具有0.1至4mm的厚度。
用水玻璃处理承载板优选地包括通过水玻璃的水溶液处理板。通常优选的是，水溶液由上述重量份的水玻璃和水来混合。在用水溶液处理之后，优选地在施加粘合剂层和其上的石料砌面之前干燥承载板。
附图说明
下面参照附图来描述本发明。其中：
图1示出根据本发明的面板的示例性层堆叠；
图2示意性地示出用于用水玻璃处理承载板的装置；和
图3示出层堆叠的另一示意图。
具体实施方式
在图1中，示出了针对根据本发明的面板20的示意性层堆叠。图示是示意性的，并未按比例绘制。特别地，承载板10大体上比附加层24、25和26更厚。此外，面板20可以包括附加层，特别是接地层、底漆层等。
在所示的示例中，承载板10具有大约8mm的厚度，并且在其周围边缘上包括耦接装置，该耦接装置分别为凹槽23和榫舌元件22的形式，然而，在图中仅示意性地示出了凹槽和榫舌元件。对于层压地板领域的技术人员来说，允许通过形状锁定来连接几个类似的面板的凹槽和榫舌元件形式的合适耦接装置是已知的。对于这种耦接装置的细节，可以例如参考同一申请人的WO 0188306或WO 0148332，其内容通过引用并入本文。通常优选的是，根据所附权利要求的承载板设置有凹槽和榫舌元件形式的耦接装置，所述凹槽和榫舌元件允许通过形状配合连接来连接几个类似的面板。优选地，在例如用水玻璃处理板之前，将耦接装置机加工到板中。
承载板10的至少前表面和后表面优选地用水玻璃处理，使得承载板10的表面设置有二氧化硅层24。在图1中，仅在前表面和后表面处示意性地示出了该层24，然而，本领域技术人员清楚的是，优选地，用水玻璃相应地处理承载板10的所有表面。将石料砌面层26施加到承载板10的前表面上。石料砌面层26通过粘合剂层25胶合到承载板10上。
在图2中，示意性地示出了通过水玻璃的水溶液处理承载板10。承载板10已经设置有耦接装置。具有多个喷嘴14的喷射装置12将热的水玻璃的水溶液喷射到承载板10的表面上。如箭头所示，承载板10在由喷嘴14提供的喷雾中转动。因此，可以确保承载板10的表面完全地并且没有任何间隙地被水玻璃的水溶液处理。
图3示意性地示出了层堆叠，并且将分别示出石料砌面层26'的粗糙度和不规则性。石料砌面层26'通过粘合剂层25'固定到承载板10上。以例如500μm的厚度施加粘合剂层25'，随后将石料砌面层26'挤压到粘合剂层25'的表面上。因此，从图3可以看出，在最终产品中，出现了不同厚度的粘合剂层。
本说明书将仅用于解释本发明，而不旨在限制本发明。而是由所附权利要求来限定保护范围。

Claims (20)

1.一种面板(20)，特别是墙壁、天花板或地板面板，所述面板(20)包括具有前表面和后表面的承载板(10)，其中，所述承载板(10)是具有3至30mm的厚度的矿棉板或纤维水泥板，其特征在于，所述承载板(10)在其所述前表面上包括粘合剂的第一层(25)以及石料砌面的第二层(26)，所述第二层具有0.1至4mm的厚度，并且通过所述粘合剂粘合到所述承载板。
2.根据权利要求1所述的面板(20)，其特征在于，在所述粘合剂层(25)和所述石料砌面层(26)之间设置附加层。
3.根据权利要求1或2所述的面板(20)，其特征在于，所述粘合剂是聚氨酯粘合剂。
4.根据前述权利要求中任一项所述的面板(20)，其特征在于，所述粘合剂层(25)的厚度为50μm至3mm、更优选为200μm至2.5mm、还更优选为300μm至2mm、最优选为500μm至2mm。
5.根据前述权利要求中任一项所述的面板(20)，其特征在于，所述粘合剂层(25)被以50μm至3mm、更优选为200μm至2.5mm、甚至更优选为200μm至2mm、最优选为500μm至2mm的厚度施加。
6.根据前述权利要求中任一项所述的面板(20)，其特征在于，所述粘合剂的量为50至5000g/m2、更优选为70至4000g/m2、甚至更优选为300至3000g/m2、最优选为500至2500g/m2。
7.根据前述权利要求中任一项所述的面板(20)，其特征在于，所述粘合剂层(25)的断裂伸长率(根据EN ISO 527-1)为100至600％、更优选为150至500％、最优选为200至400％。
8.根据前述权利要求中任一项所述的面板(20)，其特征在于，所述粘合剂层(25)具有的肖氏A硬度值(DIN EN ISO868)为25至95、更优选为27至80、最优选为30至70。
9.根据前述权利要求中任一项所述的面板(20)，其特征在于，所述粘合剂层(25)的密度在1000至1700kg/m3之间、更优选为1200至1500kg/m3之间。
10.根据前述权利要求中任一项所述的面板(20)，其特征在于，所述承载板(10)的厚度在3至20mm之间、优选为4至15mm之间、更优选为3至12mm之间、最优选为4至10mm之间。
11.根据前述权利要求中任一项所述的面板(20)，其特征在于，由矿棉制成的所述承载板(10)的密度为20至180kg/m3、优选为30至160kg/m3、更优选为40至150kg/m3、最优选为60至130kg/m3。
12.根据前述权利要求中任一项所述的面板(20)，其特征在于，由矿棉制成的所述承载板(10)具有改性表面(24)，所述改性表面能够通过用水和水玻璃、特别是硅酸钠的溶液处理所述承载板来实现。
13.根据权利要求12所述的面板(20)，其特征在于，所述水溶液由：1份水玻璃和1至10份水、优选为1份水玻璃和1.5至7份水、最优选为1份水玻璃和1.5至3份水混合[按重量计算]。
14.根据前述权利要求12或13中任一项所述的面板(20)，其特征在于，由矿棉制成所述的承载板(10)包括改性表面(24)，所述改性表面能够通过用所述水溶液喷射所述承载板或通过将所述承载板浸入所述水溶液中来实现。
15.一种用于制造面板(20)、特别是墙壁、天花板或地板面板的方法，包括以下步骤：
a.提供由矿棉制成的承载板(10)，所述承载板具有前表面和后表面；
b.用水玻璃处理所述承载板(10)；
c.通过粘合剂层(25)将石料砌面层(26)胶合到所述前表面上，所述石料砌面层具有0.1至4mm的厚度。
16.根据权利要求15所述的方法，其特征在于，通过水玻璃的水溶液来对所述承载板(10)进行所述处理。
17.根据权利要求16所述的方法，其特征在于，在处理所述承载板(10)之前，将所述水溶液进行如下混合(重量比例)：
1份水玻璃和1至10份水、优选为1份水玻璃和1.5至7份水、最优选为1份水玻璃和1.5至3份水。
18.根据权利要求16或17所述的方法，其特征在于，所述承载板(10)用所述水溶液喷射或浸入所述水溶液中。
19.根据前述方法权利要求中任一项所述的方法，其特征在于，在所述处理之后并且在将所述石料砌面层(26)胶合到所述板上之前，所述承载板(10)被干燥。
20.根据前述方法权利要求中任一项所述的方法，其特征在于，所述方法在步骤b之后包括以下步骤：施加50μm至3mm、更优选为200μm至2.5mm、甚至更优选300μm至2mm、最优选为500μm至2mm的厚度的粘合剂层(25)。
CN201880094370.2A 2018-06-08 2018-06-08 具有石料砌面的面板 Pending CN112236309A (zh)

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