CN113202252A - Floor panel and method of manufacturing a floor panel - Google Patents

Floor panel and method of manufacturing a floor panel Download PDF

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Publication number
CN113202252A
CN113202252A CN202010654484.7A CN202010654484A CN113202252A CN 113202252 A CN113202252 A CN 113202252A CN 202010654484 A CN202010654484 A CN 202010654484A CN 113202252 A CN113202252 A CN 113202252A
Authority
CN
China
Prior art keywords
core
dendritic
panel according
panel
additive
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
CN202010654484.7A
Other languages
Chinese (zh)
Inventor
托马斯·卢克·马丁·贝尔特
汤姆·范·波尔
斯万·伯恩
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
Original Assignee
Chinafloors Timber China Co 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 Chinafloors Timber China Co ltd filed Critical Chinafloors Timber China Co ltd
Publication of CN113202252A publication Critical patent/CN113202252A/en
Pending legal-status Critical Current

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Classifications

    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08LCOMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L101/00Compositions of unspecified macromolecular compounds
    • C08L101/005Dendritic macromolecules
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04FFINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00Flooring
    • E04F15/02Flooring or floor layers composed of a number of similar elements
    • E04F15/02044Separate elements for fastening to an underlayer
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04FFINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00Flooring
    • E04F15/18Separately-laid insulating layers; Other additional insulating measures; Floating floors
    • E04F15/20Separately-laid insulating layers; Other additional insulating measures; Floating floors for sound insulation
    • E04F15/206Layered panels for sound insulation
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04FFINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00Flooring
    • E04F15/02Flooring or floor layers composed of a number of similar elements
    • E04F15/10Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials
    • E04F15/102Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials of fibrous or chipped materials, e.g. bonded with synthetic resins
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04FFINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00Flooring
    • E04F15/02Flooring or floor layers composed of a number of similar elements
    • E04F15/10Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials
    • E04F15/107Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials composed of several layers, e.g. sandwich panels

Abstract

The present invention relates to a panel for constructing a floor covering or a wall covering. The panels according to the invention comprise a core comprising mineral material and comprising at least one pair of opposite side edges provided with interconnecting coupling means for interconnecting adjacent panels; the panel further comprises an additive to improve the flexibility and/or tensile strength of the panel.

Description

Floor panel and method of manufacturing a floor panel
Technical Field
The present invention relates to panels suitable for constructing floor coverings or wall coverings. The invention also relates to the use of such panels. The invention further relates to a method of manufacturing a panel suitable for constructing a floor covering or a wall covering.
Background
The flooring industry uses mostly traditional materials for making (laminated) floor tiles. Examples of commonly used materials are High Density Fiberboard (HDF) which can be consolidated together by formaldehyde or phenol-based resin, heterogeneous or homogeneous polyvinyl chloride (PVC) which may contain any plasticizers, solid hardwood chips or multi-layer veneer sheets glued together, and sintered glazed clays such as ceramics and tiles. The purpose for which these materials are used depends mainly on their material properties, such as impact resistance, stiffness, acoustic properties and/or appearance.
The interest in the use of alternative materials is relatively recent, mainly due to the market demand for more environmentally friendly or sustainable products. A major example of this is the use of mineral materials, which are often abundant resources, which are often advantageous in terms of higher compressive strength and dimensional stability as well as heat and fire resistance. They therefore have certain significant advantages compared to plastic and HDF based floor panels.
Mineral based flooring generally uses two main materials: calcium or magnesium. These materials, after processing, form the basis for hydraulic and non-hydraulic cements, respectively. The cement is usually cured into a board shape and used as a core or carrier board and laminated with the decorative layer. Calcium-based or hydraulic cement panels are characterized in that the core is made of cement based on calcium carbonate or silicates. The high alkalinity of these hydraulic calcium based cements does not allow the addition of reinforcing materials such as glass fibers. This greatly limits their popularity in the flooring industry because they are too fragile to withstand the stresses imposed on their locking mechanisms by high traffic volumes. The magnesium based panel has a core comprising a non-hydraulic cement based on magnesium oxychloride or magnesium oxysulphate. Such cements have excellent strength and fire retardant properties and are therefore widely used in the construction industry to produce fire retardant alternatives to gypsum or particle board wall panels. Recent improvements in magnesium cement technology, such as higher density, and the particular configuration of the fiber web incorporated into the board, have made it useful in floor panels. However, these magnesium substrates are generally lightweight, about 1300 to 1500kg/m3And are fragile. Like calcium-based hydraulic cements, they lack the flexibility required for floor installation, and even more so for floating installations equipped with locking mechanisms on the sides of the panels. This would require a generally accepted flexibility that,which flexibility is inherently impossible with this material.
It is therefore an object of the present invention to provide a mineral based panel with improved flexibility to allow use as a floor and to allow milling of locking mechanisms at the side edges of the floor panel.
Disclosure of Invention
To this end, the invention provides a panel suitable for constructing a floor covering or a wall covering, comprising a core, said core comprising a mineral material and comprising at least one pair of opposite side edges provided with interconnecting coupling means for interconnecting adjacent panels, wherein said core further comprises at least one dendritic additive.
The addition of the at least one dendritic additive to the mineral based core may improve the flexibility and/or tensile strength of the core. Due to the use of the dendritic additive, the yield strength of the core and thus the load-bearing strength of the panel can be increased. This improves the ability of the mineral material to be used in flooring applications. Due to this improved flexibility and/or tensile strength, it also makes it possible that the interconnecting coupling means can be applied in practice to (floor) panels having a mineral based core. The improved flexibility and/or tensile strength prevents breakage of the protruding parts of the coupling means provided at the edges of the panels when a tensile force is applied to said protruding parts. The improved flexibility and/or tensile strength can be explained by dendritic additive induced dendritic growth within the mineral-based core; at the same time, the crystal structure is destroyed and centered. This may result in obtaining a network of crystals in at least a portion of the core. The at least one dendritic additive may be present, for example, in the form of a three-dimensionally expanded flexible crystalline matrix. Thus, the dendritic additive acts as a framework for the crystallites within the mineral material. The dendritic structure in the mineral based core changes the overall material properties of the final product, i.e. the (floor) panel itself. However, the addition of the at least one dendritic additive does not adversely affect the dimensional stability and heat resistance of the panel.
The panels according to the invention are particularly suitable for use in floor coverings, wall coverings or ceiling coverings with locking mechanisms. The panels comprise at least one pair of opposite side edges provided with interconnecting coupling means for interconnecting adjacent panels. Preferably, the panel according to the invention comprises two pairs of opposite side edges provided with interconnecting coupling means. In this way, a "floating" covering can be assembled by interconnecting the individual panels to each other on all four sides, without the need for adhesives. It is also conceivable that the interconnecting coupling means comprises a tongue and a groove, wherein the tongue is provided on one of a pair of opposite side edges and the groove is provided on the other of the same pair of opposite side edges. The design of such coupling devices is well known in the art and has proven to be very suitable for panels for floor coverings, such as floating floors. In another embodiment, the interconnecting coupling means may have interlocking features that avoid free movement (play) of the interconnected panels. Such interlocking features may be protrusions and corresponding recesses provided on respective opposite side edges by which adjacent panels are interlocked with each other.
The panel according to the invention may comprise at least one top layer fixed to the core. The top layer may for example be a decorative layer. It is also conceivable that the top layer comprises a decorative layer and an abrasion resistant layer covering the decorative layer. The decorative layer may consist of a film provided with and/or printed with a decorative pattern. The decorative layer may be a paper layer and/or a polymer layer, such as a PVC layer. The wear layer is typically substantially transparent. The wear resistant layer may consist of one or more layers of transparent lacquer. Typically, the thickness of one or more layers in the panel is in the range of 0.2 to 2.0 mm. The panels according to the invention are typically laminate panels. If a decorative top layer is applied, it may for example comprise at least one cellulose-based layer, preferably paper or kraft paper, and a cured resin. The layer of cellulose-based material may also be a veneer layer adhered to the top surface of the core layer. The veneer layer is preferably selected from wood veneer, cork veneer, bamboo veneer, and the like. Other decorative top layers that may be applied to the present invention include ceramic tiles or tiles, real stone sheets, rubber sheets, decorative plastic or vinyl, linoleum and decorative thermoplastic films or foils. Possibly, the top layer may further be provided with a wear resistant layer and an optional coating. Examples of thermoplastics that can be used in such top layer are PP, PET, PVC, etc. An optional primer may also be provided on the upwardly facing surface of the core and the desired visual effect printed in a direct printing process. The decorative top layer may be further finished with a thermosetting varnish or lacquer, such as polyurethane, PUR or melamine based resins.
It is also conceivable that the panel comprises at least one backing layer fixed to the core. It is also conceivable that the panel comprises (at its back side) at least one balancing layer, which typically consists of at least one layer comprising lignocellulose and a cured resin. The panel may also comprise at least one acoustic layer, which typically consists of a low-density foam layer of Ethylene Vinyl Acetate (EVA), radiation cross-linked polyethylene (IXPE), expanded polypropylene (XPP), expanded polystyrene (XPS), but may also be a non-woven fibre, for example made of natural fibres (such as hemp or cork) or recycled/recyclable materials (such as PET or rubber). The density of the acoustic layer is preferably 65kg/m3To 300kg/m3And most preferably 80kg/m3To 150kg/m3In the meantime.
The dendritic additive may for example be a dendritic polymer. Such dendrimers may have a monodisperse or polydisperse backbone. Non-limiting examples of possible dendrimers are dendrimers, dendritic polymers, star polymers, hyperbranched polymers, dendritic grafts or linear dendrimers. The dendritic polymer is preferably non-linear. The dendritic additive may for example be a dendritic polyurethane. Other non-limiting examples of dendritic polymers are polylactic acid, polypropylene and/or polysiloxane. By definition, polymers which are mono-and/or have linear chains do not fall within the scope of the dendritic additive according to the present invention.
Preferably, the core comprises 0.1 to 10% by weight of the dendritic additive, preferably in the range of 0.5 to 5% by weight, and more preferably in the range of 1 to 2% by weight. For example, the amount of dendritic additive may be in the range of 0.7 to 2 weight percent of the total weight of the mineral material. Experiments have shown that for the purposes of the present invention, the ranges described provide the most promising results in terms of the desired material properties.
It is conceivable that the core is a multilayer core. Thus, the core may comprise at least one upper core layer and at least one lower core layer, wherein at least one core layer comprises at least one dendritic additive. Preferably, all core layers comprise at least one dendritic additive. Different core layers may have different densities. It is conceivable that the core comprises at least one reinforcement layer. In a possible embodiment, the core comprises a plurality of core layers, wherein two adjacent core layers surround the reinforcement layer. The presence of at least one reinforcing layer may further enhance the impact resistance of the core and thus of the panel. The at least one reinforcing layer may be present, for example, in the form of a reinforcing mat, film and/or mesh. The at least one reinforcing layer may, for example, comprise glass fibre, polypropylene, jute, cotton and/or polyethylene terephthalate.
At least a portion of the dendritic additive can be a nano dendritic additive. The use of the nano-dendritic additive can positively influence the crystallization of the mineral material in the core. It is also conceivable that at least a part of the dendritic additive has an average particle size in the range of 5 to 250 micrometers, preferably in the range of 50 to 100 micrometers. The surface area of the dendritic additive is, for example, 5m2G to 50m2In the range of/g.
The invention also relates to the use of the panel according to the invention. The present invention therefore relates to the use of a panel comprising dendritic particles in the core of a mineral based floor panel.
The invention further relates to a method of manufacturing a panel suitable for constructing a floor covering or a wall covering, in particular a panel according to the invention, said core being made by adding at least one dendritic additive to a mineral material.
Detailed Description
The mineral material comprising the core may for example be magnesium oxide or magnesia (MgO). The magnesium oxide may be calcined to affect the reactivity of the material. For the present invention, magnesium oxide is generally obtained by a calcination process applied at a temperature of about 600 to 1300 degrees celsius, preferably 800 to 1000 degrees celsius, to obtain reactive magnesium oxide with a relatively high reactivity. The reactive magnesium oxide is also known in the art as "caustic calcined magnesia" or light calcined magnesia. Typically, this is a highly reactive calcined MgO with a smaller grain size. This can be accomplished by combining this reactive magnesium oxide with an aqueous solution of magnesium salt (typically containing MgSO)4、MgCl2And/or MgCO3) The slurry is then mixed with additives and water to produce a magnesium cement that can be used as the primary core material. Subsequently, the slurry is cured to form a ceramic material. The ceramic cement is poured into a mold and allowed to set (typically at ambient or elevated temperature) until cured. Non-limiting examples of such cements that may be used are magnesium chloride (MOC), Magnesium Oxysulfate (MOS), or magnesium carbonate. The magnesium chloride cement can be in 5-1-8 phase (5Mg (OH)2.MgCl2.8H2O) and/or 3-1-8 phases (3Mg (OH)2.MgCl2.8H2O) is present. Both phases form needle-like or whisker-like crystals which benefit from useful properties, such as dense microstructure and high flexural strength. The magnesium oxysulfate cement may be in the 5-1-3 phase (5Mg (OH)2.MgSO4.3H2O) and/or 3-1-8 phases (3Mg (OH)2.MgSO4.8H2O) is present. The former exhibits a needle-like or whisker-like structure, typically 0.2 to 1.0 micron in diameter and 20 to 50 microns in length, while the latter exhibits a lamellar crystal structure.
Preferably, at least one dendritic additive is added to the above slurry during mixing, prior to curing. The dendritic additive can effect the formation of a three-dimensionally expanded flexible crystalline matrix which serves as a framework for the magnesium oxide crystals. Such three-dimensional expandable dendritic additives are typically composed of materials similar to or having dendrites, including linear or non-linear branched polymers, star polymers, dendritic polymers that provide an interwoven framework for the set magnesia cement crystals. When the term "dendrimer" is used, it may refer to a molecule that is repeatedly branched. Generally do not include any linear, one-dimensional and/or straight-chain polymers, such as polyethylene, nylon, polyester, PVC, PAN, alkanes, or the like.
It is also contemplated that any other crystal-based cement may be used in place of the magnesium-based core in connection with the present invention.
The method may further comprise the steps of: at least one pair of opposite side edges of the panels are provided with interconnecting coupling means for interconnecting adjacent panels. The interconnecting coupling means may be any conventional coupling means, such as the non-limiting examples described above.
The invention also relates to a method of manufacturing a panel according to the invention suitable for constructing a floor covering or a wall covering, wherein at least one dendritic additive is added to the core.

Claims (15)

1. A panel suitable for constructing a floor covering or wall covering, the panel comprising:
a core comprising mineral material and comprising at least one pair of opposite side edges provided with interconnecting coupling means for interconnecting adjacent panels,
characterized in that the core further comprises at least one dendritic additive.
2. Panel according to claim 1, comprising at least one top layer fixed on the core.
3. Panel according to any one of the preceding claims, wherein the mineral material comprises magnesium oxide, magnesium oxysulfate and/or magnesium oxychloride.
4. Panel according to any one of the preceding claims, wherein the dendritic additive is a dendritic polymer.
5. The panel according to claim 4, wherein the dendritic polymer is non-linear.
6. Panel according to any one of the preceding claims, wherein the core comprises 0.1 to 10% by weight of dendritic additive; preferably, the weight percentage of the dendritic additive is from 0.5% to 5%, and more preferably, the weight percentage of the dendritic additive is from 1% to 2%.
7. Panel according to any one of the preceding claims, wherein the core is a multilayer core.
8. The panel according to claim 7 wherein the core comprises at least one upper core layer and at least one lower core layer, wherein at least one core layer comprises at least one dendritic additive.
9. Panel according to any one of the preceding claims, wherein the core comprises at least one reinforcement layer.
10. The panel according to claim 9, wherein the reinforcement layer comprises fiberglass, polypropylene, jute, cotton, and/or polyethylene terephthalate.
11. Panel according to any one of the preceding claims, wherein the dendritic additive is a nano dendritic additive.
12. Panel according to any one of the preceding claims, wherein at least a part of the dendritic additive has an average particle size in the range of 5 to 250 micrometers, preferably in the range of 50 to 100 micrometers.
13. Use of a panel according to any one of claims 1 to 12.
14. A method of manufacturing a panel suitable for constructing a floor covering or a wall covering, in particular a panel according to any of claims 1 to 12, wherein the core is made by adding at least one dendritic additive to a mineral material.
15. The method according to claim 14, wherein at least one pair of opposite side edges of the panels are provided with interconnecting coupling means for interconnecting adjacent panels.
CN202010654484.7A 2020-01-31 2020-07-09 Floor panel and method of manufacturing a floor panel Pending CN113202252A (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
NL2024807 2020-01-31
NL2024807A NL2024807B1 (en) 2020-01-31 2020-01-31 Floor panel and method of manufacturing of a floor panel

Publications (1)

Publication Number Publication Date
CN113202252A true CN113202252A (en) 2021-08-03

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CN202010654484.7A Pending CN113202252A (en) 2020-01-31 2020-07-09 Floor panel and method of manufacturing a floor panel

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EP (1) EP4096913A1 (en)
CN (1) CN113202252A (en)
NL (1) NL2024807B1 (en)
WO (1) WO2021152154A1 (en)

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN110886463A (en) * 2018-09-10 2020-03-17 冠军联合国际公司 Floor panel comprising ceramic material or natural stone

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WO2002022520A1 (en) * 2000-09-18 2002-03-21 Rhodia Chimie Cement material comprising a dendritic polymer
CN1450980A (en) * 2000-08-09 2003-10-22 罗迪亚尼尔公司 Building material comprising a fibrous or filament reinforcement
CN101360870A (en) * 2006-01-12 2009-02-04 瓦林格创新股份有限公司 Laminate floor panels
CN102421973A (en) * 2009-04-22 2012-04-18 地板材料工业有限公司 Floor panel
EP2690142A1 (en) * 2012-07-24 2014-01-29 Armstrong World Industries, Inc. Natural based branched compositions
JP2016089379A (en) * 2014-10-30 2016-05-23 株式会社トッパン・コスモ Decorative floor sheet
CN105781061A (en) * 2014-12-16 2016-07-20 湖南邦弗特新材料技术有限公司 Novel environment-friendly waterproof wood sandwich floor
CN108884359A (en) * 2015-12-23 2018-11-23 迪亚尼亚科技有限公司 Thermo-formable polymeric product containing additive
WO2018234561A1 (en) * 2017-06-22 2018-12-27 Champion Link International Corporation Floor panel and method of producing such a floor panel

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Publication number Priority date Publication date Assignee Title
CN111133162B (en) * 2017-09-28 2022-07-08 地板工业有限公司 Panel panel

Patent Citations (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN1450980A (en) * 2000-08-09 2003-10-22 罗迪亚尼尔公司 Building material comprising a fibrous or filament reinforcement
WO2002022520A1 (en) * 2000-09-18 2002-03-21 Rhodia Chimie Cement material comprising a dendritic polymer
CN101360870A (en) * 2006-01-12 2009-02-04 瓦林格创新股份有限公司 Laminate floor panels
CN102421973A (en) * 2009-04-22 2012-04-18 地板材料工业有限公司 Floor panel
EP2690142A1 (en) * 2012-07-24 2014-01-29 Armstrong World Industries, Inc. Natural based branched compositions
JP2016089379A (en) * 2014-10-30 2016-05-23 株式会社トッパン・コスモ Decorative floor sheet
CN105781061A (en) * 2014-12-16 2016-07-20 湖南邦弗特新材料技术有限公司 Novel environment-friendly waterproof wood sandwich floor
CN108884359A (en) * 2015-12-23 2018-11-23 迪亚尼亚科技有限公司 Thermo-formable polymeric product containing additive
WO2018234561A1 (en) * 2017-06-22 2018-12-27 Champion Link International Corporation Floor panel and method of producing such a floor panel

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN110886463A (en) * 2018-09-10 2020-03-17 冠军联合国际公司 Floor panel comprising ceramic material or natural stone

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Publication number Publication date
EP4096913A1 (en) 2022-12-07
NL2024807B1 (en) 2021-09-13
WO2021152154A1 (en) 2021-08-05

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