CN113202253A - 用于形成地板覆盖物的镶板和这种地板覆盖物 - Google Patents
用于形成地板覆盖物的镶板和这种地板覆盖物 Download PDFInfo
- Publication number
- CN113202253A CN113202253A CN202010661689.8A CN202010661689A CN113202253A CN 113202253 A CN113202253 A CN 113202253A CN 202010661689 A CN202010661689 A CN 202010661689A CN 113202253 A CN113202253 A CN 113202253A
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- panel according
- panel
- magnesium
- core layer
- layer
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Abstract
本发明涉及一种适于形成地板覆盖物的镶板,特别是地板镶板,其中该镶板具有基本平坦的顶侧和基本平坦的底侧、以及包括至少一对相对的侧边缘的至少四个基本线性的侧边缘,所述侧边缘优选地设置有锁定装置。
Description
技术领域
本发明涉及适于形成地板覆盖物的镶板,特别是地板镶板。本发明还涉及这种地板覆盖物。
背景技术
地板行业通常使用一般传统的材料来制造(层压)地砖。这些材料的示例是:高密度纤维板(HDF),其可以通过甲醛或酚醛树脂合并在一起;异质或同质的聚氯乙烯(PVC),其可能包含任何增塑剂、实心硬木片;胶合在一起的多层薄板;以及烧制的配釉粘土,例如陶瓷和瓷砖。使用这些材料的目的主要取决于其材料性能,例如抗冲击性、刚性、声学性能和/或外观。但是,最近几年对替代材料的使用产生了兴趣。其示例是矿物材料的使用,因为与传统材料(例如PVC或HDF)相比,矿物材料通常具有相对较高的尺寸稳定性和足够的耐热性,并且对环境的影响较小。然而,由于其发展已经集中于用作建筑材料,特别是用作石膏/干式墙的替代物,因此它还不是特别适合用作地板镶板的部件。除了其他特征之外,期望的是由这种矿物材料制成的镶板的抗弯强度、抗冲击性、抗压痕性,内聚力和表面粘着力有所改善,使其适合用作地板镶板的部件。
发明内容
本发明的目的是提供一种复合矿物镶板、特别是地板镶板的至少一个替代性实施例,其相对于现有技术具备有竞争力的材料特性。
为此,本发明提供一种适于形成地板覆盖物的镶板,特别是地板镶板,其中,该镶板具有基本平坦的顶侧和基本平坦的底侧、以及包括至少一对相对的侧边缘的至少四个基本线性的侧边缘,该镶板包括至少一个芯层,所述至少一个芯层至少部分地包括镁晶体结构,其中所述至少一个芯层包括至少一种有机化合物,所述至少一种有机化合物包含至少两个羟基;优选地,其中所述有机化合物的存在范围为0.05%至5%的重量百分比。
芯层至少部分地包含镁晶体结构,该镁晶体结构包括至少一种包含至少两个羟基的有机化合物;优选地,其中所述有机化合物的存在范围为0.05%至5%的重量百分比,导致该晶体结构中,相比于薄片状或不规则形状的晶体而言,增加了有利的晶须或针状形状的晶体的量。
因此,本发明还涉及一种适于形成地板覆盖物的镶板,特别是地板镶板,其中,该镶板具有基本平坦的顶侧和基本平坦的底侧、包括至少一对相对的侧边缘的至少四个基本线性的侧边缘;镶板包括包含氧化镁胶粘剂的芯层,其中氧化镁胶粘剂包含薄片状或不规则形状以及晶须或针状形状的氧化镁晶体,其中晶须或针状形状的晶体比薄片状或不规则形状的晶体更多。
包括至少一个包含镁晶体结构(例如含氧硫酸镁晶须,其至少部分地形成致密的晶体微观结构)的芯层在内的芯层为镶板提供了内聚力的显著改善,并且结合有良好的抗冲击性和良好的抗弯强度。这导致镶板特别适合于地板用途。镁晶体结构包括镁晶体,优选是含氧硫酸镁晶体。
特别地,芯层包括氧化镁胶粘剂。氧化镁胶粘剂的形成和微观结构可以用“结晶”或“水合”相来描述,并用由氧化镁、镁盐(如硫酸镁或氯化镁)和水的比例组成的三元体系表示。结晶相在固化后形成为陶瓷化合物,并且可以用缩写形式表示,指的是各自在所形成的晶体中的摩尔比。以硫酸镁盐为主要粘结材料的含氧硫酸镁胶粘剂可以在环境条件下形成两个稳定的结晶相;其中之一由化合物氧化镁、硫酸镁和水组成,通常称为5相(也称为5-1-3相,表示5Mg(OH)2.MgSO4.3H2O)和3相(也称为3-1-8相,表示3Mg(OH)2.MgSO4.8H2O)。前者显示出有益的针状或晶须状晶体结构,直径为0.2–1.0μm,长度为20–50μm,具有良好的抗弯强度,而后者显示出薄片状或不规则的晶体形状,导致组合物较弱。当提到意在宜居条件下使用的含氧硫酸镁胶粘剂时,意指包含5-1-3相的含氧硫酸镁晶须的晶体相结构或3-1-8结构的含氧硫酸镁薄片的晶体相结构的陶瓷组合物。通常认为3-1-8的“薄片状”结构是在20-60℃和宜居的大气条件下更稳定的相结构。在极端压力和温度下可能会形成其他相,但在宜居温度下不稳定。当制备含氧硫酸镁胶粘剂时,自然地,至少50%的组合物由3-1-8晶体组成。其片状或不规则结构导致镶板表面风化,随后导致内聚力差和低表面粘着力,这使其特别不适合用作地板镶板中的部件。
本发明提供一种地板镶板,其包括至少一个芯层,该芯层的含氧硫酸镁5-1-3“晶须”相与3-1-8“薄片”相的比例大于1。
含氧硫酸镁晶须的优点是在环境条件下形成。含氧硫酸镁晶须也可称为晶针。由于含氧硫酸镁晶须至少部分地形成晶体结构,所以含氧硫酸镁晶须将彼此互锁以形成高密度的微观结构。这些互锁晶须从而为镶板的芯层提供了改进的强度。另外,由于存在具有良好抗冲击性的所述芯层,因此根据本发明的板是有益的;例如,当在根据本发明的地板覆盖物中应用多个镶板时,这是有利的。当根据EN 310进行测试时,5-1-3相的晶体结构的抗压缩和压痕性高于50MPa,而3-1-8结构的抗压缩和压痕性仅为约20MPa。由于晶须不易溶于水,而3-1-8相在湿润条件下的稳定性较差,因此本发明的镶板还具有良好的耐水性和耐湿性。
对于本领域技术人员而言,含氧硫酸镁晶须不是在本发明目的的芯材料中使用的和形成晶体结构的明显材料。技术人员通常会使用更常见的也可以形成晶相的(含氧)氯化镁胶粘剂,其中氯化镁晶须能够以5-1-8(5Mg(OH)2.MgCl2.8H2O)相和/或3-1-8(3Mg(OH)2.MgCl2.8H2O)相存在。然而,这些氯化镁晶体相对不耐水,因为水可能浸出可溶性氯化镁,这可能导致材料强度的显著降低。含氧硫酸镁晶须没有这个缺点。作为提供其他添加剂来改善材料特性的替代,本发明提供了不同的材料。然而,不排除根据本发明的地板镶板包含相对较小比例的氯化镁,例如至多5%的重量百分比,优选小于1%的重量百分比。
含氧硫酸镁晶须可以通过将反应性氧化镁与硫酸镁水溶液混合而制得。所述反应性氧化镁可以通过在600至1300摄氏度范围内、优选在800至1000摄氏度范围内的温度下进行的煅烧工艺而获得。反应性氧化镁(RM)也可以称为“苛性煅烧氧化镁(CCM)”或轻烧氧化镁。
形成所需的MOS晶须的第一个条件是原料的比例。通过将MgSO4与水以0.6-2:1的比例混合来制备镁盐水溶液,将其搅拌约2分钟以使其溶解,从而使混合物在固化期间形成陶瓷材料。为了确保晶须晶相与薄片晶相的比例大于1,MgO与MgSO4的比例应保持在4.6-5.8:1左右,更理想的是4.9-5.2。形成所需晶体结构的第二个条件是向浆料中添加重量百分比为0.05%至10%的第二水溶液,该第二水溶液包含重量百分比为50%至90%的包含至少两个羟基(-OH)的有机化合物。这包括包含羟基(例如羧基(-COOH))的官能团,这些官能团对MOS晶须晶体的形成具有相同的作用。含有两个羧基官能团-COOH的二元羧酸取得了最佳结果,最有利的是短链长,例如草酸C2H2O4(两个羧基-COOH基团)或中草酸C3H2O5(基于水的存在的两个到四个羧基-COOH基团))。柠檬酸C6H8O7(四个–OH羟基)和硼酸H3BO3(三个–OH羟基)也获得了良好的结果。已经发现,至少一部分这些元素的添加会影响芯层的晶体结构,并增加和增强MgO结晶成优选的晶相,这对于可预见的用作地板镶板是有利的。也可以考虑使用磷酸。
将该陶瓷材料或陶瓷胶粘剂与添加剂的混合物倒入模具中,并使其在环境温度或高温下凝固,直至固化。固化的材料具有良好的强度和良好的阻燃性能,从而导致该材料特别适合用于建筑工业。然而,也可以通过水热合成由硫酸镁和氢氧化镁制造含氧硫酸镁晶须。
根据本发明的镶板通常具有芯层,该芯层的厚度在3至10毫米的范围内。所述芯层的密度通常为1200-1500kg/m3,更具体地为1300-1400kg/m3左右。本发明的一个实施例可以由多层的含氧硫酸镁胶粘剂构成,其中每层都具有特定的晶体结构,有利的是至少顶层中的5-1-3MOS晶须相与3-1-8MOS晶须相的比例大于1,或者顶层与底层具有类似的比例,或者基本上整个芯层由这样类似的比例组成,这取决于所讨论的地板镶板的具体要求。应当理解,在一个实施例中,芯的不同层可以具有不同的晶体结构比,以增强声学性能。
镶板具有基本平坦的顶侧和基本平坦的底侧、以及包括至少一对相对的侧边缘的至少四个基本线性的侧边缘。镶板通常是大致矩形或正方形的。然而,也可以设想镶板具有大致平行四边形的形状。当提到镶板时,它既可以是地板镶板也可以是墙壁镶板。术语“砖”可与术语“镶板”互换。
至少多个含氧硫酸镁晶须的长径比通常至少为5,优选至少为10,更优选至少为20。在这种实施例中,含氧硫酸镁晶须可以为镶板的芯层提供足够的(抗弯)强度。可能地,至少一些含氧硫酸镁晶须的平均直径在0.2至1.0微米的范围内和/或至少一些含氧硫酸镁晶须的平均长度在1至50微米的范围内。由于在给定的温度和湿度下含氧硫酸镁晶须稳定时的相,所以含氧硫酸镁晶须的确切形状可能会有所不同。
不需要芯层中的含氧硫酸镁晶须在几乎整个芯层上形成晶体结构。实际上,在优选实施例中,芯层包含晶须相晶体结构的重量百分比为至少50%、优选为至少55%、更优选为至少60%的含氧硫酸镁晶须。芯层的另一体积可以具有非晶体结构。芯层的另一体积例如可以是至少部分多孔的。在一些实施例中,如果芯层的一部分包含重量百分比低于50%的含氧硫酸镁晶须的晶体结构,则是有利的。较高的百分比可能导致芯层的机械强度降低,从而导致镶板的机械强度降低。
在可能的实施例中,芯层包括上部和下部以及位于芯层的所述上部和所述下部之间的加强层。芯层的上部甚至可以限定基本平坦的顶侧,并且芯层的底部可以限定镶板的基本平坦的底侧。至少一个加强层的存在可以导致镶板的声学特性的改善。例如,这可以导致改善的声音衰减特性。至少一个加强层的存在也可以有助于镶板本身的强度提高。加强层可以例如包括织造或非织造纤维材料。在有利的实施例中,加强层可以包括玻璃纤维。加强层可以特别地包括玻璃纤维网。其非限制性示例是具有至少5×5mm的网眼尺寸的玻璃纤维网和/或具有至少90g/m2的面积重量的玻璃纤维网。在可能的实施例中,玻璃纤维网可以设置有涂层,以防止物理接触期间的皮肤反应。可以想到的是,加强层的厚度约为0.2至0.4毫米。
在另一个可能的实施例中,芯层还包括中部和另一加强层,其中第一加强层位于芯层的所述上部和所述中部之间,第二加强层位于所述芯层的所述中部和所述下部之间。第一加强层和第二加强层都可以由如上所述的加强层组成。芯层的中部不是必须具有与芯层的其他部分相同的材料特性。例如可以想到的是,芯层的中部至少部分地发泡。因此,中部可以包含发泡剂。芯层的这种至少部分发泡的中部可以进一步改善镶板的声学性能。
在优选实施例中,镶板包括两对相对的侧边缘,所述相对的侧边缘设置有互连的联接装置。当组装例如地板覆盖物时,这将有助于容易地连接多个镶板。互连的联接装置通常包括榫舌和凹槽,其中榫舌设置在一对相对的侧边缘中的一个侧边缘上,而凹槽设置在同一对相对的侧边缘中的另一个侧边缘上。共同作用的镶板的互连联接装置可以设置有共同作用的锁定元件。
在根据本发明的镶板的可能的实施例中,芯层还包括至少一种聚合物和/或木基材料。还可以想到的是,芯层还包含至少一种粘结剂。
镶板还可以包括至少一个顶层。顶层通常设置在镶板的顶面上。有利的是,顶层具有适合其预期用途(例如防水层、耐磨层和/或装饰层)的特性。所述顶层可以例如经由粘合剂、热熔材料和/或热压或冷压直接或间接地附接到镶板的芯层。如果应用了装饰性顶层,则其例如可以包括至少一层基于纤维素的层和固化树脂,其中基于纤维素的层优选是纸或牛皮纸。所述基于纤维素的材料的层也可以是粘附到芯层的顶表面的单板层。该单板层优选选自木薄板、软木薄板、竹薄板等。可以应用于本发明的其他装饰性顶层包括瓷砖或瓷质砖、真正的石材薄板、橡胶薄板、装饰性塑料或乙烯基、油毡和装饰性热塑性膜或箔。可能地,顶层可以进一步设置有耐磨层和可选的涂层。可以在这种顶层中使用的热塑性塑料的示例是PP、PET、PVC等。还可以在芯的面向上的表面上提供可选的底漆,并在直接印刷过程中印刷所需的视觉效果。装饰性顶层可以用热固性清漆或漆(例如聚氨酯、PUR或三聚氰胺基树脂)进一步涂饰。
在另一可能的实施例中,镶板包括至少一个背衬层。这可以是与(地板)镶板一起使用的任何合适的背衬层。还可以想到的是,镶板(在其背面)包括至少一个平衡层,该平衡层通常由至少一个包含木质纤维素和固化树脂的层组成。镶板还可以包括至少一个声学层,该声学层通常由乙烯-乙酸乙烯酯(EVA)、辐射交联的聚乙烯(IXPE)、发泡聚丙烯(XPP)、发泡聚苯乙烯(XPS)的低密度泡沫层组成,但也可以是非织造纤维,例如由天然纤维(如大麻或软木)或回收/可回收材料(如PET)制成。该声学层的密度优选地在65kg/m3至300kg/m3之间,最优选地在80kg/m3至150kg/m3之间。
本发明还涉及一种地板覆盖物,其包括多个根据前述权利要求中任一项所述的镶板,特别是地板镶板。然而,包括多个根据本发明的镶板的墙壁覆盖物也落入本发明的范围内。
附图说明
将基于在以下附图中示出的非限制性示例性实施例阐明本发明。在附图中:
图1是根据本发明的镶板的第一可能实施例;
图2是根据本发明的镶板的第二可能实施例;以及
图3是根据本发明的镶板的第三可能实施例。
具体实施方式
图1示出了根据本发明的镶板101的第一实施例的横截面的示意图。该图显示了镶板101,其包括芯层102,芯层102包含至少部分地形成晶体结构104的含氧硫酸镁晶须103。可以看出,含氧硫酸镁晶须103彼此互锁。镶板101还包括顶层105和可选的背衬层106。
图2示出了根据本发明的镶板201的第二可能实施例的横截面的示意图。该图示出了镶板,该镶板包括:芯层202,其包括上部202a和下部202b;以及加强层207,加强层207位于芯层202的所述上部202a和所述下部202b之间。芯层202的两个部分202a、202b均包含至少部分地形成晶体结构204的含氧硫酸镁晶须203。可以看出,芯层202的总体积中仅一部分包括晶体结构204。加强层207包括玻璃纤维网。镶板201还包括顶层205。
图3示出了根据本发明的镶板301的第三可能实施例的横截面的示意图。该图示出了包括芯层302的镶板,其中芯层302分别包括上部302a、下部302b和中部302c。这些部分被多个加强层307a、307b分开。在本实施例中,芯层302的中部302c是泡沫层。芯层102的其他部分302a、302b包括含氧硫酸镁晶须303,含氧硫酸镁晶须303至少部分地形成晶体结构304。镶板301还包括顶层305。
显然,本发明不限于在此示出和描述的实施例,而是在所附权利要求的范围内可以有对本领域技术人员而言显而易见的许多变型。
在本专利公开中使用的动词“包括”及其变化形式应理解为不仅意味着“包括”,还应理解为意指短语“包含”、“基本上由……组成”、“由……形成”及其变化形式。
Claims (19)
1.一种适于形成地板覆盖物的镶板,特别是地板镶板,其中,所述镶板具有基本平坦的顶侧和基本平坦的底侧、以及包括至少一对相对的侧边缘的至少四个基本线性的侧边缘,
所述镶板包括:
至少一个芯层,所述至少一个芯层至少部分地包括镁晶体结构,
其中所述至少一个芯层包括重量百分比为0.05%至5%的至少一种有机化合物,所述至少一种有机化合物包含至少两个羟基。
2.根据权利要求1所述的镶板,其中,所述镁晶体结构是含氧硫酸镁和/或含氧氯化镁晶体结构。
3.根据前述权利要求中任一项所述的镶板,其中,所述镁晶体的至少一部分以长的互锁晶体结构或“晶须”存在,并且一些所述镁晶体以短的不规则晶体结构或“薄片”存在。
4.根据前述权利要求中任一项所述的镶板,其中,晶须相与薄片晶体相的比例高于1。
5.根据前述权利要求中任一项所述的镶板,其中,至少多个镁晶体的长径比至少为5,优选至少为10,更优选至少为20。
6.根据前述权利要求中任一项所述的镶板,其中,至少多个含氧硫酸镁晶体、特别是含氧硫酸镁晶须的平均直径在0.2至1.0微米的范围内。
7.根据前述权利要求中任一项所述的镶板,其中,至少多个含氧硫酸镁晶体、特别是含氧硫酸镁晶须的平均长度在1至50微米的范围内。
8.根据前述权利要求中任一项所述的镶板,其中,所述芯层包括重量百分比为至少5%的含氧硫酸镁晶须,优选重量百分比为至少10%、更优选重量百分比为至少20%的晶须相晶体结构。
9.根据前述权利要求中任一项所述的镶板,其中,包含至少两个羟基(-OH)的所述有机化合物是酸,例如草酸、柠檬酸、磷酸、硼酸。
10.根据前述权利要求中任一项所述的镶板,其中,所述芯层包括上部和下部以及位于所述芯层的所述上部和所述下部之间的加强层。
11.根据权利要求10所述的镶板,其中,所述加强层包括玻璃纤维。
12.根据权利要求10至11中任一项所述的镶板,其中,上部加强层包括玻璃纤维网。
13.根据权利要求10至12中任一项所述的镶板,其中,所述芯层包括中部和另外的加强层,其中第一加强层位于所述芯层的所述上部和所述中部之间,并且第二加强层位于所述芯层的所述中部和所述下部之间。
14.根据前述权利要求中任一项所述的镶板,包括设置有互连的联接装置的两对相对的侧边缘。
15.根据前述权利要求中任一项所述的镶板,其中,所述互连的联接装置包括榫舌和凹槽,其中所述榫舌设置在一对相对的侧边缘中的一个侧边缘上,而所述凹槽设置在同一对相对的侧边缘中的另一个侧边缘上。
16.根据前述权利要求中任一项所述的镶板,其中,所述芯层还包含至少一种粘结剂。
17.根据前述权利要求中任一项所述的镶板,包括至少一个顶层,所述顶层包括至少一个装饰层和/或保护层。
18.根据前述权利要求中任一项所述的镶板,包括至少一个可选的背衬层,用于改善平衡和/或声学性能。
19.一种地板覆盖物,包括多个根据前述权利要求中任一项所述的镶板,特别是地板镶板。
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