CN113404251A - 复合防水地板和墙盖板 - Google Patents

复合防水地板和墙盖板 Download PDF

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Publication number
CN113404251A
CN113404251A CN202011473540.3A CN202011473540A CN113404251A CN 113404251 A CN113404251 A CN 113404251A CN 202011473540 A CN202011473540 A CN 202011473540A CN 113404251 A CN113404251 A CN 113404251A
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CN
China
Prior art keywords
composite
waterproof
flakes
plastic
rigid
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Pending
Application number
CN202011473540.3A
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English (en)
Inventor
P.V.多彻
P.埃拉穆斯佩
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.)
Shaw Indusries Group Inc
Shaw Industries Group Inc
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Shaw Indusries Group Inc
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Publication of CN113404251A publication Critical patent/CN113404251A/zh
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Abstract

本申请涉及复合防水地板和墙盖板。复合防水板包括：刚性惰性芯，所述刚性惰性芯包括塑料复合物，所述塑料复合物包括至少20%的塑料，所述塑料选自由高密度聚乙烯和聚氯乙烯所组成的组；装饰薄片层，所述装饰薄片层粘接至所述刚性惰性芯的顶表面，其中，所述装饰薄片层是防水的并且被封装在树脂中以使得所述装饰薄片层防水且耐磨损；第一防水粘合剂层，所述第一防水粘合剂层使所述刚性惰性芯与所述装饰薄片层结合；以及所述复合防水板具有带有侧向延伸入所述刚性惰性芯的槽的第一边缘，以及带有从所述刚性惰性芯延伸的舌的第二相对边缘。根据本发明制造的板和面板具有更好的尺寸稳定性。

Description

复合防水地板和墙盖板
本案为分案申请，其母案申请号为201380055155.9，国际申请日为2013年9月13日，发明名称为复合防水地板和墙盖板。
技术领域
本发明涉及地板，且具体而言涉及一种利用竹和塑料的新且改良的防水地板。
背景技术
在地板产业中，迫切需求的是呈现木地板外观的防水地板。具体而言，该地板不仅需要防潮，还需经济，容易安装，容易保养并且能舒适地在其上行走。
在地板产业中，使用纤维板或颗粒板的层压地板来作为芯层获得了巨大的市场份额。此层压地板制成后具有许多期望的特性，例如，价格合理，耐污，耐磨，容易保养和防火。此外，层压地板能够承载多种类型的印刷设计，包括木纹设计。
天然木地板，特别是橡木地板以及其它硬木地板被采用作为地板材料已有几个世纪。尽管不如层压地板经济，但木地板的外观和舒适性是非常受欢迎的。层压地板和木地板两者的最大缺点之一是其在持续暴露于湿气时的性能。在木地板的情况中，湿气将造成地板的鼓起(swelling)和变形，造成不平的表面且甚至造成板之间的间隙。在层压地板的情况中，持续暴露于湿气往往将使纤维板或颗粒板材料完整性不稳定，对层压板造成永久且不可修复的损害。这导致许多地板安装者避免在反复或长期经受湿气的区域使用层压地板，如房屋的厨房，浴室，洗衣间以及地下室区域，或餐馆和一些零售店等商业设施。
由于木地板和层压地板的不足，在潮湿区域的地板选择通常被局限于瓷砖，石材以及橡胶或乙烯基地板。对于瓷砖和石材而言，视觉选择是受限的，材料和安装的成本是相对高的，并且所得的地板在不存在底板辐射热时是阴冷的，且不适于长时间地站立。橡胶和乙烯基地板可能相对便宜，然而因为这些地板材料并非刚性，底板的缺陷通过橡胶和乙烯基传递，并且表现在地板表面上，这可能不美观。此外，用于橡胶和乙烯基地板的粘合剂的强度可由于湿气而受损，这可导致卷曲损害，因为地板缺乏刚性。
为解决这些问题，层压地板被制成具有改良的耐潮性，这通过选择三聚氰胺(melamine)，异氰酸盐(isocyanate)或酚(phenolic)的粘合剂并且通过应用防水材料和硅树脂填缝剂(silicone caulking)来密封空隙。然而，这些步骤仍然是不足够的，这是因为增加的安装时间和制造成本，以及因为这些防水尝试并非100%有效。一种生产适合的层压板的尝试在美国专利号No.7,763,345以及其相关申请中描述，其中生产出热塑性材料的芯，并且印刷层和保护盖层施加在顶侧上。热塑性材料的芯通常是刚性聚氯乙烯复合物，且芯被压制成具有腔以提供缓冲。然而，压制的板具有杯凸(cup)的趋势，并且即使具有腔，PVC的热塑性芯并不便宜。
在现代建筑中，还期望的是利用绿色或可循环材料以使建筑的环境成本最小化。因此，期望的是在可能时最大化地使用循环材料或废料。因此，存在对于改善的防水复合(engineered)地板和墙盖材料的需求。
发明内容
本发明的特征在于提供一种刚性防水地板或墙盖板，其包括如下可能性：多种可视表面外观，刚性和相对环境友好的芯以及缓冲的背衬。根据本发明的复合板可有利地利用锁定系统以便地板可咬接到一起作为浮筑地板(floating floor)，采用浮筑地板安装方法，其中不需要粘合剂来将地板结合至底板。此外，主要的复合防水板材料可包括竹屑，木屑或软木屑，其基本为其它地板制造工序的副产物。
通过将竹，木或软木屑或其组合与高密度聚乙烯(HDPE)或聚氯乙烯(原生(virgin)，循环或原生和循环聚氯乙烯的混合物)结合，提供了刚性且惰性的芯，其不会吸收湿气并且不会扩张或收缩，因此消除了突峰和间隙的形成。
附图说明
本发明的具体特征和优点以及其它目的将通过结合附图的以下描述而变得明显，在附图中：
图1是根据本发明的示例性复合防水地板的透视图。
图2是根据本发明的示例性地板的分解截面图。
图3a-d描绘了示例性现有技术的喀哒锁定(click-lock)的边缘构造，其可有利地与根据本发明制造的各种板一起使用。
具体实施方式
总体而言，本发明涉及防水复合地板或墙板。在图1中示出的示例性地板10的端视图示出了板的三个重要结构性部件。具体而言，顶表面是薄片层，例如耐磨层20，其为防水的并且选自多种可能的材料，包括砖或石材薄片(veneer)；橡胶；装饰塑料；装饰乙烯基；油毡；以及封装在乙烯基或树脂中的任何材料(如，软木，竹或木薄片)，以致使层防水且耐磨损。装饰乙烯基耐磨层特别地在成本和性能上是有效益的。该表面不仅耐潮，并且还能提供有根据ASTM C 1028-96的大约0.68的静摩擦系数(CoF)，并且对于大多应用而言至少大约0.60的摩擦系数是期望的。
复合板10的中间区段或芯30由大约在55至80%之间且优选在大约70%的竹屑，木屑，软木屑或它们的混合物形成。剩余的20至45%包括高密度聚乙烯(HDPE)或备选地，原生PVC或循环PVC或原生PVC和循环PVC的组合，以及至多大约10%的化学添加剂，例如防UV剂，防氧化剂，稳定剂，着色剂，防真菌剂，偶联剂，增强剂，以及润滑剂。碳酸钙也可添加入作为填充物。在屑以及HDPE或PVC和添加剂和填充物混合且融合后，复合材料被压成期望的尺寸。这类HDPE和屑复合物以前主要被制造成用作外门板，栏杆和栅栏，但至今为止未以以下方式使用：即在视觉上足够吸引人或商业上成功地用于住宅或商业地板。相反，这些木-塑料或竹-塑料复合物依照有限的调色板被浸着上颜色，其适于且仅推广用于外部使用。在本发明中使用时，一些添加剂，例如防UV剂，防真菌剂以及杀虫剂是不需要的。并且，至今为止，软木屑并非塑料复合物的主要成分。通常添加大量木或竹屑为所得的板提供更好的刚性，而软木屑即使在塑料混合物中也保持一些弹性。芯30可为实心或如期望，特别是在相对厚的实施例中可设有通道。
衬底层40附接至压制的屑和塑料的芯30上，并且也由防水或耐水材料制成，例如软木，橡胶，泡沫或防水平衡纸(balancing paper)。
板10还具有开槽端50，其具有轮廓51和通道52，其与具有轮廓61和突起62的突起端60匹配。具体轮廓根据优选设计来制造以便允许板快速锁定到一起，通常这不需要使用粘合剂。然而，如期望，粘合剂可施加在轮廓上，由此将板结合到一起，以便产生邻近板的更永久的结合。匹配轮廓可为在图3a-d中所描绘的喀哒锁定类的或更传统的通常需使用粘合剂的舌与槽结构。
图2是本发明的板或墙面板可能包括的各个层的分解视图。顶层21是可选的保护性上覆层或盖层，在耐磨层20并非特别耐磨时更期望该上覆层或盖层。优选地顶层特征包括：透明度，硬度以及耐划伤性。用于顶层21的示例性材料包括具有氧化铝的三聚氰胺甲醛树脂和聚氨酯。在耐磨层20包括耐性材料，例如砖或石材时或在耐磨层20已包括保护硬化物，例如具有树脂或乙烯基封装的竹，木或软木的情况中，耐磨层20可能更少受益于顶层21。
结合层22将耐磨层20结合至芯30，并且通常为耐水粘合剂。优选的粘合剂类型是热熔粘合剂，其可在复合地板或墙盖制造期间在大于200℉且更通常大于250℉的温度下施加，并且因此不适于方便地在住所或商用建筑中在安装地板时使用。热熔粘合剂应当是耐水的或在严重或长期暴露于湿气时近乎不可渗透的。
另一结合层41使衬底层40与芯30结合。如第一结合层22，第二结合层41也优选为近乎不透湿气的热熔粘合剂。衬底层40选自各种可能的材料，这取决于地板或墙盖板的价格方面和功能性。
根据本发明的板有利地设有喀哒锁定边缘系统，例如与通道52协作的突起62，以及边缘轮廓51,61。Pervan的美国专利No.6,023,907和Morian的美国专利No. 6,006,486公开了两种前缘紧固系统。图3a-d示出各种其它喀哒锁定边缘。图3a中的系统可成角度且咬接(angeled and snapped)。图3b示出了咬接头，图3c可成角度且咬接，但通常具有相比图3a的系统更低的结合强度。图3d也示出锁定和合拢面板，其中被安装的第一面板具有在右边缘上的通道，且第二面板为成角度的，使得其突起进入通道并且两个面板的顶缘接触，并且随后向下旋转第二面板，直到轮廓锁定。在使用喀哒锁定边缘时，相对容易安装浮筑地板而无须粘合剂。对于具体的板优选的具体的边缘系统可取决于板的尺寸和刚性来改变。还应理解根据本发明的板和面板可使用粘合剂安装，且粘合剂可施加以结合板的边缘或以将板附接至底板或墙或两者上。
根据本发明的板和面板通常为矩形，其具有至多大约一英寸的厚度并且具有在大约2至12英寸之间的宽度。通常地板将具有比墙盖板或面板更大的厚度。循环木，软木或竹屑的使用通过负责的资源管理对持续发展做出贡献，并且使用所提供的竹，软木或持续收获的木的结果是环境友好的建筑材料。
根据本发明制造的板和面板近乎不会鼓起，并且具有更好的尺寸稳定性。这些板和面板呈现出由于湿气的尺寸变化小于0.01%。产品还可制造成具有小于0.25mm的长度，宽度和直线度公差，并且许多适合的耐磨层提供不褪色且可清洁的表面。
本领域技术人员将领会到本文公开结构的各种备选方案。然而，应当理解本公开内容涉及本发明的优选实施例，其仅出于示例目的并且不应视为本发明的限制。不偏离本发明精神的所有这些修改都应包括在所附权利要求的范围之内。

Claims (19)

1.一种复合防水板，包括：
(a)刚性惰性芯，所述刚性惰性芯包括塑料复合物，所述塑料复合物包括至少20%的塑料，所述塑料选自由高密度聚乙烯和聚氯乙烯所组成的组；
(b)装饰薄片层，所述装饰薄片层粘接至所述刚性惰性芯的顶表面，其中，所述装饰薄片层是防水的并且被封装在树脂中以使得所述装饰薄片层防水且耐磨损；
(c)第一防水粘合剂层，所述第一防水粘合剂层使所述刚性惰性芯与所述装饰薄片层结合；以及
(d)所述复合防水板具有带有侧向延伸入所述刚性惰性芯的槽的第一边缘，以及带有从所述刚性惰性芯延伸的舌的第二相对边缘。
2.根据权利要求1所述的复合防水板，其特征在于，所述刚性惰性芯使得所述复合防水板在暴露于湿气时鼓起小于0.01%。
3.根据权利要求1所述的复合防水板，其特征在于，所述塑料复合物还包括填充物。
4.根据权利要求3所述的复合防水板，其特征在于，所述填充物包括碳酸钙。
5.根据权利要求1所述的复合防水板，其特征在于，所述塑料复合物还包括添加剂，所述添加剂选自由防UV剂，防氧化剂，稳定剂，着色剂，防真菌剂，偶联剂，增强剂和润滑剂所组成的组。
6.根据权利要求1所述的复合防水板，其特征在于，所述板具有根据ASTM C 1028-96测量至少为0.60的静摩擦系数。
7.一种复合防水板，包括：
防水刚性芯，所述防水刚性芯包括：木屑，塑料和碳酸钙填充物；
薄片层，所述薄片层设置在所述防水刚性芯的顶表面上；
其中，所述薄片层选自由木薄片，软木薄片，竹薄片，砖薄片，石材薄片，橡胶薄片，装饰塑料薄片，油毡薄片和装饰乙烯基薄片所组成的组；并且
其中，所述薄片层通过防水的结合来结合至防水刚性芯的顶表面；以及
设置在所述薄片层上的保护盖层，所述保护盖层选自由带有氧化铝的三聚氰胺甲醛树脂和聚氨酯所组成的组。
8.根据权利要求7所述的复合板，其特征在于，所述防水刚性芯还包括添加剂，所述添加剂选自由防UV剂，防氧化剂，稳定剂，着色剂，防真菌剂，偶联剂，增强剂和润滑剂所组成的组。
9.根据权利要求7所述的复合板，其特征在于，所述塑料选自由高密度聚乙烯和聚氯乙烯所组成的组。
10.根据权利要求7所述的复合板，其特征在于，所述塑料复合物包括：(a)20%至45%的塑料，所述塑料选自由高密度聚乙烯和聚氯乙烯所组成的组，以及(b)填充物。
11.根据权利要求7所述的复合板，其特征在于，暴露于湿气导致所述板的鼓起的尺寸小于0.01%。
12.根据权利要求7所述的复合板，其特征在于，所述复合板包括地板和墙板中的一者。
13.根据权利要求7所述的复合板，其特征在于，所述复合板还包括带有侧向延伸入所述防水刚性芯的槽的第一边缘，以及带有从所述防水刚性芯延伸的舌的第二相对边缘。
14.一种复合板，包括：
刚性惰性芯，所述刚性惰性芯至少是防水的和耐水的中的一者，
其中，所述刚性惰性芯包括塑料复合物，
其中，所述塑料复合物还包括塑料和填充物，以及
其中，所述填充物是碳酸钙；
薄片层，所述薄片层设置在所述刚性惰性芯的顶表面上，
其中，所述薄片层选自由木薄片，软木薄片，竹薄片，砖薄片，石材薄片，橡胶薄片，装饰塑料薄片，油毡薄片和装饰乙烯基薄片所组成的组，以及
其中，所述薄片层通过防水的结合来结合至所述刚性惰性芯的顶表面；
设置在所述薄片层上的保护盖层，所述保护盖层选自由带有氧化铝的三聚氰胺甲醛树脂和聚氨酯所组成的组；以及
所述板具有带有侧向延伸入所述刚性惰性芯的槽的第一边缘，以及带有从所述刚性惰性芯延伸的舌的第二相对边缘。
15.根据权利要求14所述的复合板，其特征在于，所述防水的结合包括耐水粘合剂。
16.根据权利要求14所述的复合板，其特征在于，所述塑料选自由高密度聚乙烯和聚氯乙烯所组成的组。
17.根据权利要求14所述的复合板，其特征在于，所述塑料复合物包括：(a)20%至45%的塑料，所述塑料选自由高密度聚乙烯和聚氯乙烯所组成的组，以及(b)填充物。
18.根据权利要求14所述的复合板，其特征在于，所述复合板包括地板和墙板中的一者。
19.根据权利要求14所述的复合板，其特征在于，所述复合板还包括衬底层，所述衬底层选自由软木，橡胶，泡沫和防水平衡纸所组成的组，其中
防水粘合剂层将所述衬底层结合至所述防水芯的底表面。
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