CN114929468A - 绝缘镶板和制造绝缘镶板的方法 - Google Patents
绝缘镶板和制造绝缘镶板的方法 Download PDFInfo
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- CN114929468A CN114929468A CN202180008592.XA CN202180008592A CN114929468A CN 114929468 A CN114929468 A CN 114929468A CN 202180008592 A CN202180008592 A CN 202180008592A CN 114929468 A CN114929468 A CN 114929468A
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Abstract
本发明涉及一种绝缘镶板,特别是墙壁镶板或屋顶镶板,其包括发泡芯层和固定至发泡芯层的覆盖层。本发明还涉及一种绝缘覆盖物,特别是墙壁覆盖物或地板覆盖物,其包括多个所述绝缘镶板。
Description
技术领域
本发明涉及一种绝缘镶板,特别是墙壁镶板或屋顶镶板。本发明还涉及一种绝缘覆盖物,特别是墙壁覆盖物或地板覆盖物,其包括多个所述绝缘镶板。本发明还涉及一种制造绝缘镶板、特别是墙壁镶板或屋顶镶板的方法。
背景技术
通常,绝缘泡沫材料应用于地板覆盖物(特别是浮动地板)下方的隔热和隔音层,或者例如应用于墙壁覆盖物的后面。泡沫材料可以是闭孔泡沫材料或开孔泡沫材料,并且通常至少部分地由聚氨酯制成。可以应用由固体泡沫材料制成的预制镶板,但也可以想象通过喷涂以半液体形式应用绝缘材料。对这些材料日益关心的一个主题是可能有害的挥发性和半挥发性物质的迁移,这主要是由于当今改进的或高效建造的房屋通风有限。使用(有害)化学物质的建筑材料可能会影响建筑物的室内空气质量,从而影响暴露于其中的人们的健康。在安装期间或使用喷涂泡沫建筑材料期间发现了一个主要风险,其中发现(挥发性)化学物质在通过皮肤吸收或被吸入时会引起皮肤、眼睛和肺部刺激、哮喘以及化学过敏。当聚氨酯完全反应或固化时,它基本上是稳定的,并且它的化学性质不是重要的担忧问题。然而,一些产品(如粘合剂、涂料和喷涂泡沫)在建筑工人或房主进行绝缘改造时施加则会发生反应,并在之后继续反应几个小时,并且可能含有人们可能接触到的未固化的异氰酸酯。异氰酸酯(例如亚甲基二苯基二异氰酸酯)是与多元醇反应形成聚氨酯的化学物质,并以其毒性特点而闻名。使用聚氨酯基材料的另一个问题是关于可回收性的讨论。聚氨酯的焚烧会产生有毒气体,但聚氨酯的物理和化学回收都存在一些技术和经济上的困难。因此,需要用全天然材料代替现有的聚氨酯基泡沫材料作为可再生的、天然来源的绝缘层。
发明内容
本发明的第一个目的是提供一种对基于合成聚合物的绝缘镶板的木基替代物,而不损害镶板性能。
本发明的第二个目的是提供一种改进的木基绝缘镶板。
本发明的第三个目的是提供一种改进的木基绝缘镶板,其具有优于传统聚氨酯基泡沫材料的改善性能。
这些目的中的至少一个可以通过提供一种绝缘镶板、特别是墙壁镶板或屋顶镶板或地板镶板来实现,该绝缘镶板包括:
包括至少一个发泡芯层的芯部,其中发泡芯层至少部分地由木质泡沫制成;以及
直接或间接地固定至发泡芯层的至少一个覆盖层。
使用包含木质泡沫的发泡芯层与固定至发泡芯层的覆盖层的组合具有若干优点。然而,首先从木质泡沫本身的优点开始,该材料具有高耐火性、优异的声音衰减或隔音性能以及良好的隔热性能,同时仍然是一种完全木基的材料。此外,由于其低密度,木质泡沫是一种极其轻质的材料。实验发现,木质泡沫具有足够的耐湿性,从而在浸没在水中时产生最小的弯曲或翘曲。由于木质泡沫的上述品质,该材料特别适合用作屋顶覆盖物、天花板覆盖物和/或墙壁覆盖物的隔热层和/或隔音层。木质泡沫不属于复合材料,因此其与木质聚合物复合材料(WPC)不同,这是因为木质泡沫仅基于木材,没有将木质纤维与合成聚合物(如PVC、PU、合成树脂或合成胶水)混合。木质泡沫结构可以部分地归因于木质纤维之间的天然化学键合,这可以通过在生产过程中添加的过氧化氢来引发。然而,这些化学力本身不足以提供足够的机械强度。作为木质泡沫结构的成因的第二个因素是木质纤维(束)之间的物理锚固和缠结。例如,未经处理的木质纤维具有非常光滑的表面,而为了提供锚固,纤维应该被粗糙化。例如,这可以通过在精炼机中研磨基材来完成,该精炼机使木质纤维变粗糙,从而将它们的表面分解至它们不再能够彼此滑过的状态。通过粗糙化的木质纤维的天然化学键合,可以产生具有相对较高机械强度的木质泡沫,这种泡沫可以在不使用任何粘合剂的情况下生产。木质泡沫通常具有基本上开孔的结构。发泡芯层优选为防水层。硬木和软木以及其他木质纤维素都是生产木质泡沫的合适原材料。特别地,该材料优异的隔热性能使其非常适合用作绝缘镶板、特别是墙壁镶板或屋顶镶板的芯层材料。其高耐火性增强了适用性。事实上,如果发生火灾,绝缘镶板会闷烧,但也有助于火的熄灭。从环境和安全的角度来看,使火熄灭是相当有利的。
使用直接或间接地固定至发泡芯层的至少一个覆盖层是有利的,因为这样的覆盖层能够为发泡芯层提供保护功能。在根据本发明的镶板中使用这两个层还具有几个技术优势。由于发泡芯层和覆盖层的重量相对较轻,因此将它们结合起来形成了适合应用于多个建筑区域的相对轻质的镶板。材料相对较高的柔性允许用作弯曲的或成形的墙壁镶板,或者例如用作天花板镶板。这些镶板也可以用作外墙覆层,这是因为由于其重量和密度低,使得墙壁上的整体负载可以保持较低。这还使得安装更容易,包括可能使用替代的连接系统,因为可能不需要传统的螺钉和/或钉子连接件。然而,用螺钉和/或钉子来固定根据本发明的镶板也是可能的。此外,所使用的材料的组合也适用于例如锯切和胶合。
木质泡沫的材料选择也具有传统天然材料的若干优点。木质泡沫的好处是相对较高的透气性,允许以受控方式释放捕获的水分。缺乏透气性是雪松或其他可能导致木材腐烂的传统木质材料的常见问题。镶板优选地在发泡芯层和覆盖层中都包含天然材料,这从环境的角度来看是理想的。覆盖层通常为木质泡沫发泡芯层提供保护功能。根据本发明的镶板的室内和室外应用,以及用于家庭的干燥和潮湿区域(例如在浴室中),都是可以想象的。包含木质泡沫的发泡芯层可以有助于表面水平的平衡。这在用于地板时特别有利,因为可以省略额外的地板下方层的使用,但在应用于墙壁或屋顶结构时也可能有用。发泡芯层的木质泡沫优选构造成使得能够获得对于建筑应用所需的隔音和/或隔热性能。因此,可以想象,根据本发明的镶板替代了使用具有单独隔绝(聚氨酯)层的传统地板镶板、墙壁镶板或天花板镶板。根据本发明的镶板具有良好的产品寿命预期。但是,如果应当移除镶板,由于镶板的至少芯层是基本木基的,因此回收也相当简单。此外,该镶板甚至为基于聚氨酯的产品提供了价格具有竞争力的替代品,特别是对于更具环保和健康意识的消费者而言。在另一个可能的实施例中,可以想象,至少一个发泡芯层基本上完全由木质泡沫制成。
通常,至少一个发泡芯层的密度在30kg/m3至300kg/m3之间,优选在40kg/m3至250kg/m3之间。这里,机械强度随木质泡沫的密度而变化:密度越高,纤维彼此越靠近,并且木材自己的结合和缠结锚固就越强。因此,更高的密度可以导致更高的机械强度。然而,由于木质泡沫中的内部锚固,即使是相对较低的密度也可以为绝缘镶板提供足够的强度,同时提供相当轻质的镶板。进一步例如可以想象,至少一个发泡芯层的密度在30kg/m3至300kg/m3之间,优选在40kg/m3至250kg/m3之间。然而,也可以想象,至少一个发泡芯层的密度在40kg/m3至200kg/m3之间,或40kg/m3至150kg/m3之间,或40kg/m3至100kg/m3之间。还可以想象,至少一个发泡芯层的密度在30kg/m3或40kg/m3至70kg/m3或80kg/m3之间。
如上所述,在根据本发明的镶板的优选实施例中,至少一个发泡芯层基本上不含树脂、粘结剂和/或胶水。这样的实施例是有利的,因为可以消除源于来自任何这样的添加剂的排放物的健康担忧。发泡芯层优选还不含任何其他(化学)合成添加剂,例如合成聚合物。甚至可以想象的是,发泡芯层仅由木质泡沫、特别是木质纤维和/或木束组成。如果绝缘镶板本身基本上不含树脂、粘结剂和/或胶水,也是有利的。发泡芯层的木质泡沫通常由化学键合的木质纤维组成,其中木质纤维另外通过木质纤维和/或木质纤维束的物理锚固和缠结而结合。
在一个可能的实施例中,绝缘镶板的至少一个覆盖层至少部分地由致密木材制成。对于可能包括致密木材的覆盖层,使用这种材料层有若干优点。致密木材显著增强了木材的机械性能。致密木材可以通过工程工艺获得,下面给出其示例。技术上可以将木材压缩到其原始厚度的20%,从而实现所谓的完全致密化。本发明范围内的致密化通常是指被压缩至其原始厚度的至少50%,优选至少40%,更优选至少30%。为了获得这种致密木材,首先将天然木材在NaOH/Na2SO3溶液中煮沸,以获得更加多孔和柔韧的木材。然后在至少100℃的温度下垂直于其生长方向压缩木材。该过程通常涉及部分地去除木材的半纤维素和木质素(木材中较硬的成分),这些成分是将木材细胞保持在一起的胶水。完全去除这些成分可能会导致材料质量不佳,这表明仍然需要一些木质素来粘合木材。木材的纤维素保持完整,并且紧密间隔的纤维素纳米纤维之间的氢键增强了致密木材的强度。因此,覆盖层的致密木材优选由化学处理过的压缩木材组成。优选地,覆盖层的致密木材包含小于10wt.%(重量百分数)的半纤维素和/或小于15wt.%的木质素。通过该工艺获得的致密木材是相当稳定的类型,在潮湿条件下不会受到影响,使其适用于天花板和天花板结构,但也例如适用于地板。此外,除了材料的优异机械性能之外,致密木材也是一种相对轻质的材料,这对建筑用途是有利的。由于其相对较高的耐刮擦性,致密木材也适合作为覆盖层。除了术语“致密木材”之外,还可以使用术语“压缩木材”。致密木材可以是径向致密木材和/或切向致密木材。优选地,覆盖层的致密木材至少部分地由硬木组成,例如桤木、轻木、山毛榉木、山核桃木、桃花心木、枫木、橡木、柚木、胡桃木、橡木和/或杨木。用于制作覆盖层的硬木优选来自非单子叶植物的被子植物或开花植物。通常,致密木材是防水的。因此,覆盖层优选为防水层。例如还可以想象,至少一个覆盖层基本上完全由致密木材制成。
特别地,如果致密木材层用作覆盖层,则可以想象这样的实施例,其中:至少一个发泡芯层和至少一个覆盖层熔合在一起。以这种方式,可以省略粘合剂和/或偶联剂和/或偶联材料的使用。由于发泡芯层和覆盖层都包含木基材料,因此可以将所述层熔合在一起。例如,熔合可以是热熔合,通过施加热量来完成。芯层和覆盖层的熔合通常导致所述层之间的牢固和结实的连接。分层的变化也可以显著减少。然而,仍可以想象的是,覆盖层被胶合到发泡芯层上。
还可以想象,至少一个覆盖层至少部分地由金属材料制成。至少部分地由金属材料制成的覆盖层可以为木质泡沫提供保护功能。例如可以想象,木质泡沫芯层涂有金属材料。例如,(部分地)金属覆盖层也可能是相对刚性的,例如是金属片,使得金属覆盖层可以形成金属外壳的至少一部分。在后一种情况下,绝缘镶板可以容易至少部分地结构化。例如,镶板的至少一个表面可以设置有结构化图案。例如,这可能有助于将镶板用作屋顶镶板。使用至少部分地由金属材料制成的覆盖层还可以使包括(互连的)联接部分变得容易。还可以想象,至少一个覆盖层包括金属箔。金属箔的非限制性示例是铝箔、锡箔、金属薄片和/或复合材料薄片。金属箔的存在可以进一步增强镶板的绝缘特性。另一种可能性是存在至少一个至少部分地由天然纤维制成的覆盖层。非限制性示例是竹、大麻、亚麻制品、亚麻纤维、黄麻、剑麻、椰子和/或香蕉纤维。天然纤维可以例如至少部分地以(编织)垫的形式存在。根据所使用的类型,天然纤维可能具有良好的防潮性能、良好的弹性、良好的温度调节性能和/或者甚至是抗菌的。此外,由于高可持续性和低污染物,天然纤维通常具有良好的生态足迹。因此,木质泡沫和天然纤维的组合有助于镶板的环保特性和/或易回收性。
可能地,发泡芯层包括至少一种支撑结构。这种支撑结构可以例如用作有助于和/或支撑发泡芯层的空间取向的距离元件。例如,至少一个支撑元件可以基本上嵌入在发泡芯层内。
木质泡沫例如可以是开孔泡沫。木质泡沫的开孔泡沫结构有助于发泡芯层的透气性,从而有助于绝缘镶板的透气性。然而,也可以想象,木质泡沫是闭孔泡沫。进一步可以想象,至少一个发泡芯层包括由单一类型的木材制成的木质泡沫。使用由单一类型的木材制成的木质泡沫的一个优点是生产成本可能更低。还可以使用多种类型的木材来生产木质泡沫。如上所述,木质泡沫可以例如由软木或硬木或两者的组合制成。可用于制造用于发泡芯层的木质泡沫的可能的木材类型的非限制性示例是:山毛榉木和/或松木。
镶板还可以包括多个发泡芯层,其中每个发泡芯层都包含木质泡沫。在这样的实施例中,每个发泡芯层可以具有不同的密度。提供包括多个发泡芯层的镶板并且每个发泡芯层都包含木质泡沫可能是有利的,因为由此能够以相对容易的方式调节诸如刚度之类的材料特性。所述多个发泡芯层可以例如通过熔合工艺相互连接。其优点是可以避免粘合剂的使用。在另一个可能的实施例中,镶板可以包括至少一个中间层,该中间层优选地被包围在至少两个发泡芯层之间,其中该中间层更优选地包括致密木材。这种构型将使得能够构造具有上述衰减和隔绝特性的轻质镶板,但具有基本上刚性的脊部以增加抗扭刚度和刚性。
如上所述,芯部优选包括至少一个中间层。将一个或多个中间层添加到芯部通常会改善芯部的声学和/或结构特性,从而改善镶板本身的声学和/或结构特性。优选地,至少一个中间层被至少一个发泡芯层至少部分地包围。更优选地,至少一个中间层并且优选是每个中间层基本上完全被其他芯部材料包围,特别是被一个或多个发泡芯层包围。优选地,至少一个中间层嵌入在发泡芯层中或嵌入在芯部的两个相邻的发泡芯层之间。优选地,中间层构造成用作加强层。这有助于使镶板适合用作屋顶镶板、墙壁镶板或地板镶板。这也使得更容易对镶板边缘进行成型,特别是使镶板适合与另一个镶板互连。优选地,至少一个中间层包含互连的纤维。更优选地,中间层形成纤维垫,纤维垫可以是编织垫或非编织垫。通常,纤维通过树脂例如热固性树脂相互连接。优选地,中间层包含选自下组的(合成)纤维:玻璃纤维、碳纤维和/或芳族聚酰胺纤维。优选地,中间层包含选自下组的天然纤维:亚麻、黄麻、大麻、蕉麻、苎麻、纤维素和/或洋麻。因此,优选地,至少一个中间层是开孔层和/或多孔层,优选地是编织垫或非编织垫。优选地,至少一个发泡芯层穿透中间层或至少一部分存在于中间层中的孔。可以想象,芯部包括至少两个发泡芯(子)层,所述发泡芯(子)层通过所述中间层中的通孔相互连接。优选地,芯部具有厚度T,并且其中芯部包括多个嵌入的加强层,特别是玻璃纤维层,所述加强层位于芯部的由0.5T限定的中心线的两侧。在应用单个中间层的情况下,该中间层可以定位在芯部的中心线处。可替代地,可以将单个中间层定位在芯部的上部(这通常是优选的)或芯部的下部。
优选地,在镶板的生产过程中,将至少一个中间层定位在水性木浆中以转化为基于木质泡沫的发泡芯层,然后将木浆干燥并转化为发泡芯层,从而得到发泡芯层,具有嵌入其中的所述中间层。这也可以被认为是一个优选实施例,其中芯部包括多个一体连接的发泡层,该发泡层结合有至少一个中间层。
优选地,生产基于木质泡沫的发泡芯层通过切削木材并进一步研磨木材直至形成木屑而进行。加水并加热这种混合物通常会产生木浆。这种包含木质纤维素的悬浮液还包含半纤维素和木质素,并且通常还包含另外的木材残留物。随后可以将后一种残留物部分活化以充当粘结剂(胶水),用于在干燥过程中粘结木材颗粒/纤维。悬浮液发泡成泡沫通常通过泡沫稳定剂如蛋白质以及通过对悬浮液充气和(通常在80至140摄氏度范围内的温度下)干燥悬浮液进行。该方法非常适合于在悬浮液中引入至少一个中间层并在发泡和干燥期间将中间层嵌入最终的发泡芯层中。
代替开孔中间层,可选地,芯部还可以另外包括至少一个闭孔中间层。可以想象,中间层至少部分地由致密木材制成。
优选地,至少一个发泡芯层的厚度为0.5cm至20cm,优选为1cm至15cm,更优选为2cm至10cm。实验发现,根据本发明的具有这种厚度的发泡芯层具有良好的绝缘性能,同时还为镶板本身提供了足够的稳定性。根据所需的应用和所需的材料特性,可以选择发泡芯层的厚度。例如,相对较厚的发泡芯层可以提供改进的(热)绝缘性能。
通常,覆盖层具有至少800kg/m3、优选至少900kg/m3、更优选至少1000kg/m3的密度。覆盖层的密度通常显著高于至少一个发泡芯层的密度。覆盖层可以具有1mm至7mm的厚度,优选2mm至5mm的厚度。然而,如果使用(金属)箔作为覆盖层,那么其厚度甚至可能低于1mm。覆盖层可能胶合在发泡芯层上。因此,至少一个发泡芯层和至少一个覆盖层可以胶合在一起。如果使用胶水,优选使用天然的和/或无毒的胶水。这种天然胶水例如可以由有机来源如天然树脂和糊精制成。
可能地,至少一个覆盖层的上表面积超过发泡芯层的上表面积。可替代地,(一个或多个)覆盖层可以在偏移位置附接至(一个或多个)发泡芯层。这两种选择通常更容易使一个或多个边缘、优选是覆盖层的边缘成型,以便在安装期间允许镶板相互连接。事实上,根据本发明的镶板还可以包括至少一对相对的侧边缘,所述侧边缘设置有互连的联接装置。这样的互连的联接装置可以例如是榫舌-凹槽组合。互连的联接装置可以设置在至少一个发泡芯层和/或至少一个覆盖层中。
在另一个有利的实施例中,镶板包括至少两个覆盖层,所述至少两个覆盖层都直接或间接地固定在所述至少一个发泡芯层的顶部的相对侧上。因此,基本上可以获得这样一种夹层结构,其中:至少一个发泡芯层基本上被至少两个覆盖层包围。还可以想象,发泡芯层基本上被(一个或多个)覆盖层包围。在这样的实施例中,覆盖层可以进一步实施其保护功能。
在一个优选实施例中,至少一个覆盖层直接或间接地固定在至少一个发泡芯层的上方。这里,装饰性顶表面(如果应用了)可以并且优选地至少部分地由覆盖层形成。为了保护覆盖层,可以使用保护涂层。特别是在覆盖层包括致密木材的情况下,这种保护涂层可以是油基涂层。还可以想象,覆盖层设有油基涂层。对覆盖层施加油基涂层可以增强覆盖层的尺寸稳定性。在极端潮湿的条件下,例如在大约95%的湿度下,致密木材可能会稍微变弱和/或膨胀。油基涂层可以防止这种膨胀,从而为覆盖层提供保护涂层。还可以想象,至少一个发泡芯层直接或间接地固定在至少一个覆盖层的上方。
还可能优选的是,镶板包括直接或间接地固定在覆盖层和/或发泡芯层的上方的装饰性顶部基板,其中装饰性顶部基板构成镶板的装饰性顶表面。顶部基板可以由单层或多层组成。优选地,在施加了的情况下,顶部基板包括至少一个印刷层和/或覆盖所述印刷层的至少一个保护(顶)层。印刷层和/或保护层的存在可以防止镶板、特别是防止覆盖层因刮擦和/或环境因素(如紫外线/湿气)和/或磨损和撕裂而可能损坏。还可以想象,如果覆盖层包括致密木材,则在施加至少一个印刷层和/或保护层之前,为所述致密木材覆盖层提供油基涂层。印刷层可以由在其上施加了装饰性印刷图案的薄膜形成,其中薄膜被固定在覆盖层和/或发泡芯层上。印刷层也可以由至少一个油墨层形成,该油墨层直接施加到覆盖层、发泡芯层的顶表面上,或施加到施加在覆盖层和/或发泡芯层上的底漆层上。
在另一个可能的实施例中,绝缘镶板可以包括附接到发泡芯层的下侧的至少一个背衬层。背衬层可以例如为镶板提供稳定性和/或保护。背衬层可以例如包括多孔天然层,特别是多孔纤维素。使用多孔纤维素背衬层将使得能够在制造过程中从包含木质泡沫的发泡芯层中蒸发出水分,同时还允许(半)多孔背衬层与墙壁或天花板或屋顶结构的一部分接触,这可以提供有关镶板透气性的优势。这种多孔背衬层的存在可以使对流热辐射更多地吸收到包含木质泡沫的发泡芯层中。也可以应用另一种天然纤维材料作为背衬层,例如但不限于基于PLA的非编织结构。然而,背衬层也可以是无孔的天然层,优选是无孔的水蒸气阻隔层。这种层的一个可能的非限制性示例是无孔纤维素。对于水分含量相对较高的区域(例如浴室),无孔背衬层可以防止水分进入包含木质泡沫的发泡芯层。多孔背衬材料和无孔背衬材料都需要由耐热结构或晶体结构(优选为生物基材料)制造,以便能够经受用于制造包含木质泡沫的发泡芯层的干燥条件。
进一步可能的是,至少一个发泡芯层包含至少一种矿物材料,特别是胶结剂。在发泡芯层中使用至少一种矿物材料作为填料可以降低发泡芯层的吸水率。例如,可以在发泡芯层中施加5wt.%(重量百分数)至15wt.%的矿物材料。木质泡沫对吸水率很敏感,这是不希望的,因为它会促进真菌的侵袭。使用至少一种矿物材料(特别是以所述量使用)可以显著降低木质泡沫的吸水率。在发泡芯层中使用至少一种矿物材料也可以导致发泡芯层的密度更高。也能够想到应用至少一种疏水添加剂(例如硅烷和/或蜡)来代替矿物材料。然而,所述疏水添加剂将对发泡芯层的强度具有不利影响。
优选地,镶板的每个层都是基本防水层。优选地,装饰性镶板本身是防水镶板。优选地,绝缘镶板本身是热稳定(耐温)镶板。
在根据本发明的装饰性镶板的优选实施例中,该镶板不含任何覆盖层。在根据本发明的绝缘镶板的另一个优选实施例中,该镶板不含任何基于木质泡沫的发泡芯层。
优选地,至少一个镶板层,特别是至少一个发泡芯层和/或至少一个装饰性覆盖层,包含和/或涂有至少一种抗微生物剂。一种或多种加入的抗微生物剂抑制了细菌、真菌、微生物和其他病原体或非病原体的生长,并且通常随时间而迁移到砖片表面,从而建立控制与砖片表面接触的微生物的生长的浓度梯度。优选地,抗微生物剂选自:(i)有机或有机金属抗微生物物质,例如卤代苯基醚、卤代水杨酰苯胺、倍半萜醇、卤代碳酰替苯胺、双酚化合物、一般酚类、甲醛、季铵化合物、吡啶衍生物以及六氯酚;和/或(ii)无机抗微生物物质,包括玻璃或陶瓷基质中的银、锌或铜,其中抗微生物剂优选包含2,4,4’-三氯-2’-羟基二苯醚。所述抗微生物剂还可以是选自下组的化学物质:三氯生,邻苯基苯酚,二碘甲基对甲苯砜,吡啶硫酮锌,吡啶硫酮钠,唑类(吡咯)如丙环唑,聚(六亚甲基双胍)盐酸盐,3,4,4’三氯碳酰替苯胺,一水合钡,以及沸石或无定形玻璃粉末中的银、铜或锌。在发泡层的生产过程中,可以想象且相当实用的是,将至少一种抗微生物剂与木质泡沫(或与前体木浆悬浮液)混合。
本发明还涉及一种绝缘覆盖物,特别是绝缘墙壁覆盖物、绝缘天花板覆盖物,或绝缘屋顶覆盖物,或绝缘地板覆盖物,其包括多个根据本发明的绝缘镶板。如上所述,由于层的相对较高的柔性,覆盖物能够以弯曲或成形的构造应用。
本发明还涉及一种制造绝缘镶板的方法,所述绝缘镶板特别是墙壁镶板或屋顶镶板,优选是根据本发明的绝缘镶板,所述方法包括以下步骤:
a)提供包括上侧和下侧的至少一个发泡芯层,其中所述发泡芯层包含木质泡沫;
b)提供包括致密木材的至少一个装饰性覆盖层;以及
c)将至少一个覆盖层固定至发泡芯层的上侧和/或下侧。
将在下面呈现的一组非限制性条款中进一步说明本发明的实施例。
1.一种绝缘镶板,特别是墙壁镶板、屋顶镶板或地板镶板,所述绝缘镶板包括:
包括至少一个发泡芯层的芯部,其中所述发泡芯层至少部分地由木质泡沫制成;以及
直接或间接地固定至发泡芯层的至少一个覆盖层。
2.根据条款1所述的镶板,其中,至少一个发泡芯层的密度在30kg/m3至300kg/m3之间,优选在40kg/m3至250kg/m3之间。
3.根据前述条款中任一项所述的镶板,其中,至少一个发泡芯层基本上不含树脂、粘结剂和/或胶水。
4.根据前述条款中任一项所述的镶板,其中,至少一个发泡芯层基本上不含任何合成聚合物。
5.根据前述条款中任一项所述的镶板,其中,发泡芯层的木质泡沫由化学键合的木质纤维组成,并且其中木质纤维另外通过木质纤维和/或木质纤维束的物理锚固和缠结而结合。
6.根据前述条款中任一项所述的镶板,其中,至少一个覆盖层至少部分地由致密木材制成。
7.根据前述条款中任一项所述的镶板,其中,至少一个覆盖层至少部分地由金属材料制成。
8.根据前述条款中任一项所述的镶板,其中,至少一个覆盖层包括金属箔。
9.根据前述条款中任一项所述的镶板,其中,至少一个覆盖层至少部分地由天然纤维制成。
10.根据前述条款中任一项所述的镶板,其中,发泡芯层包括至少一个支撑结构。
11.根据前述条款中任一项所述的镶板,其中,木质泡沫是开孔泡沫。
12.根据前述条款中任一项所述的镶板,其中,镶板包括多个发泡芯层,其中每个发泡芯层均包含木质泡沫。
13.根据前述条款中的一项所述的镶板,其中,芯部包括至少一个中间层。
14.根据条款13所述的镶板,其中,至少一个中间层被至少一个发泡芯层至少部分地包围。
15.根据条款13或14所述的镶板,其中,至少一个中间层嵌入在发泡芯层中或嵌入在两个相邻的发泡芯层之间。
16.根据条款13至15中任一项所述的镶板,其中,中间层构造成用作加强层。
17.根据条款13至16中任一项所述的镶板,其中,中间层包含互连的纤维。
18.根据条款13至17中的一项所述的镶板,其中,中间层包含选自下组的纤维:玻璃纤维、碳纤维和/或芳族聚酰胺纤维。
19.根据条款13至18中的一项所述的镶板,其中,中间层包含选自下组的天然纤维:亚麻、黄麻、大麻、蕉麻、苎麻、纤维素和/或洋麻。
20.根据条款13至19中的一项所述的镶板,其中,中间层是开孔层和/或多孔层,优选地是编织垫或非编织垫。
21.根据条款13至20中的一项所述的镶板,其中,至少一个发泡芯层穿透中间层。
22.根据条款13至21中的一项所述的镶板,其中,芯部包括至少两个发泡芯层,所述发泡芯层通过所述中间层中的通孔相互连接。
23.根据条款13至22中的一项所述的镶板,其中,芯部包括多个一体连接的发泡层,所述发泡层结合有至少一个中间层。
24.根据条款13至23中的一项所述的镶板,其中,芯部具有厚度T,并且其中芯部包括多个嵌入的加强层,特别是玻璃纤维层,所述加强层位于所述芯部的由0.5T限定的中心线的两侧。
25.根据条款13至24中任一项所述的镶板,其中,芯部包括至少一个封闭层。
26.根据条款13至25中任一项所述的镶板,其中,中间层至少部分地由致密木材制成。
27.根据前述条款中任一项所述的镶板,其中,至少一个发泡芯层的厚度为0.5cm至20cm,优选为1cm至15cm,更优选为2cm至10cm。
28.根据前述条款中任一项所述的镶板,其中,覆盖层具有至少800kg/m3、优选至少900kg/m3、更优选至少1000kg/m3的密度。
29.根据前述条款中任一项所述的镶板,其中,覆盖层的厚度为1mm至10mm,优选为2mm至7mm。
30.根据前述条款中任一项所述的镶板,其中,至少一个发泡芯层和至少一个覆盖层熔合在一起。
31.根据前述条款中任一项所述的镶板,其中,至少一个发泡芯层和至少一个覆盖层胶合在一起。
32.根据前述条款中任一项所述的镶板,其中,覆盖层的上表面积超过发泡芯层的上表面积。
33.根据前述条款中任一项所述的镶板,其中,所述镶板包括至少两个覆盖层,所述覆盖层都直接或间接地固定至所述至少一个发泡芯层的顶部的相对侧。
34.根据前述条款中任一项所述的镶板,其中,所述镶板包括至少一对相对的侧边缘,所述侧边缘设置有互连的联接装置。
35.根据前述条款中任一项所述的镶板,其中,至少一个发泡芯层包含矿物材料,特别是胶结剂。
36.根据前述条款中任一项所述的镶板,其中,镶板的每一层都是基本防水的层。
37.根据前述条款中任一项所述的镶板,其中,镶板没有任何覆盖层。
38.根据前述条款中任一项所述的镶板,其中,镶板没有任何基于木质泡沫的发泡芯层。
39.一种绝缘覆盖物,特别是墙壁覆盖物或地板覆盖物,所述绝缘覆盖物包括多个根据条款1至38中任一项所述的绝缘镶板。
40.一种制造绝缘镶板的方法,所述绝缘镶板特别是墙壁镶板或屋顶镶板,优选是根据条款1至38中任一项所述的绝缘镶板,所述方法包括以下步骤:
a)提供包括上侧和下侧的至少一个发泡芯层,其中所述发泡芯层包含木质泡沫;
b)提供包括致密木材的至少一个装饰性覆盖层;以及
c)将至少一个覆盖层固定至发泡芯层的上侧和/或下侧。
附图说明
将在以下附图中所示的非限制的示例性实施例的基础上阐述本发明。在附图中:
图1是根据本发明的绝缘镶板的第一可能实施例的立体图;
图2是根据本发明的绝缘镶板的第二可能实施例的立体图;
图3是根据本发明的绝缘镶板的第三可能实施例的截面图;
图4是根据本发明的绝缘镶板的第四可能实施例的截面图;以及
图5是根据本发明的绝缘镶板的第五可能实施例的截面图。
具体实施方式
图1示出了绝缘镶板100,其包括至少部分地由木质泡沫制成的发泡芯层101,以及固定至发泡芯层101的覆盖层102。镶板100可以例如用作墙壁镶板或屋顶镶板。发泡芯层101包括上侧101a和下侧101b。覆盖层102固定在发泡芯层101的所述上侧101a上。发泡芯层101包含木质泡沫,木质泡沫优选地具有基本开孔的结构。覆盖层102包括致密木材。在所示实施例中,覆盖层102直接附接到发泡芯层101,特别是通过熔合来附接。
图2示出了根据本发明的绝缘镶板200的第二可能实施例的立体图。镶板200包括木质泡沫芯层201和两个覆盖层202a、202b。实际上,芯层201基本上被包围在覆盖层202a、202b之间。在所示实施例中,覆盖层202a、202b由金属材料制成。因此,发泡芯层201的木质泡沫被覆盖层202a、202b遮蔽。金属覆盖层202a、202b实际上形成围绕芯层201的金属外壳。每个覆盖层202a、202b的上表面积都超过发泡芯层201的上表面积。镶板200(特别是覆盖层202a、202b)设置有互连的联接装置203,以使得能够更容易地安装镶板。所示实施例的镶板200设有结构化的上表面,并且镶板的下表面也略微结构化。这也有助于绝缘镶板200的易用性,例如在作为屋顶镶板200的应用中。
图3示出了根据本发明的绝缘镶板300的第三可能实施例的截面图。镶板300包括发泡芯层301和覆盖层302,其中发泡芯层301包含木质泡沫,覆盖层302通过粘合剂层304附接至发泡芯层。可选地,镶板300包括附接至发泡芯层301的下侧的背衬层305。同样可选地,镶板300可以包括印刷层306和/或至少一个保护层307。
图4示出了根据本发明的绝缘镶板400的第四可能实施例的截面图。包含木质泡沫的发泡芯层401附接到由金属箔制成的覆盖层402。可以看出,发泡芯层401的厚度df明显大于覆盖层402的厚度dc。
图5示出了根据本发明的绝缘镶板500的第五可能实施例的截面图。镶板500包括覆盖层502。镶板500还包括至少一个中间层508,中间层508被包围在两个发泡芯层501a、501b之间。中间层508可以包括致密木材和/或基于纤维的加强层,并且可以设置有互连的联接轮廓(未示出)。还可以想象,中间层508包含另一种天然材料,例如选自下组的优选相互连接的天然纤维:亚麻、黄麻、大麻、蕉麻、苎麻、纤维素和/或洋麻。
代替天然纤维,也可以使用合成纤维,如玻璃纤维、碳纤维和/或芳族聚酰胺纤维。如果中间层508包含优选互连的纤维并且构成开孔层和/或多孔层(优选是编织垫或非编织垫),则其被发泡芯层501a、501b中的一个或两个穿透。优选地,发泡芯层501a、501b通过形成在中间层508中的通孔相互连接。在该实施例中,示出了中间层508位于镶板500的芯部的中心线处,其中芯部由下发泡芯层501b、中间层508和上发泡芯层501a的层压体形成。
通过若干说明性实施例描述了上述发明构思。可以想象,也可以在不应用所描述的示例的其他细节的情况下应用各个发明构思。没有必要详细说明上述发明构思的所有能够想到的组合的示例,因为本领域技术人员将理解的是,可以(重新)组合许多发明构思以达到特定应用。
显然,本发明不限于本文所示和描述的工作示例,而是在所附权利要求的范围内可能存在很多变型,这些变型对于本领域技术人员来说是显而易见的。当使用术语“绝缘镶板”时,它也可以称为“用于绝缘的镶板”。根据本发明的绝缘镶板通常也适合用作地板镶板。
本专利中使用的动词“包括”及其变型应理解为不仅意指“包括”,而且还应理解为意指短语“包含”、“基本上由……组成”、“由……形成”及其变型。
Claims (41)
1.一种绝缘镶板,特别是墙壁镶板或屋顶镶板,所述绝缘镶板包括:
包括至少一个发泡芯层的芯部,其中所述发泡芯层至少部分地由木质泡沫制成,并且所述芯部包括至少一个中间层;以及
至少一个覆盖层,所述至少一个覆盖层直接或间接地固定至所述芯部,特别是固定至所述芯部的至少一个发泡芯层。
2.根据权利要求1所述的镶板,其中,至少一个中间层被至少一个发泡芯层至少部分地包围。
3.根据权利要求1或2所述的镶板,其中,至少一个中间层嵌入在发泡芯层中或嵌入在两个相邻的发泡芯层之间。
4.根据前述权利要求中任一项所述的镶板,其中,所述中间层构造成用作加强层。
5.根据前述权利要求中任一项所述的镶板,其中,所述中间层包含互连的纤维。
6.根据前述权利要求中的一项所述的镶板,其中,所述中间层包含选自下组的纤维:玻璃纤维、碳纤维和/或芳族聚酰胺纤维。
7.根据前述权利要求中的一项所述的镶板,其中,所述中间层包含选自下组的天然纤维:亚麻、黄麻、大麻、蕉麻、苎麻、纤维素和/或洋麻。
8.根据前述权利要求中的一项所述的镶板,其中,所述中间层是开孔层和/或多孔层,优选地是编织垫或非编织垫。
9.根据前述权利要求中的一项所述的镶板,其中,至少一个发泡芯层穿透所述中间层。
10.根据前述权利要求中的一项所述的镶板,其中,所述芯部包括至少两个发泡芯层,所述发泡芯层通过所述中间层中的通孔相互连接。
11.根据前述权利要求中的一项所述的镶板,其中,所述芯部包括多个一体连接的发泡层,所述发泡层结合有至少一个中间层。
12.根据前述权利要求中的一项所述的镶板,其中,所述芯部具有厚度T,并且所述芯部包括多个嵌入的加强层,特别是玻璃纤维层,所述加强层位于所述芯部的由0.5T限定的中心线的两侧。
13.根据前述权利要求中任一项所述的镶板,其中,所述芯部包括至少一个封闭层。
14.根据前述权利要求中任一项所述的镶板,其中,所述中间层至少部分地由致密木材制成。
15.根据前述权利要求中任一项所述的镶板,其中,至少一个发泡芯层的密度在30kg/m3至300kg/m3之间,优选在40kg/m3至250kg/m3之间。
16.根据前述权利要求中任一项所述的镶板,其中,至少一个发泡芯层基本上不含树脂、粘结剂和/或胶水。
17.根据前述权利要求中任一项所述的镶板,其中,至少一个发泡芯层基本上不含任何合成聚合物。
18.根据前述权利要求中任一项所述的镶板,其中,所述发泡芯层的木质泡沫由化学键合的木质纤维组成,并且其中所述木质纤维另外通过木质纤维和/或木质纤维束的物理锚固和缠结而结合。
19.根据前述权利要求中任一项所述的镶板,其中,至少一个覆盖层至少部分地由致密木材制成。
20.根据前述权利要求中任一项所述的镶板,其中,至少一个覆盖层至少部分地由金属材料制成。
21.根据前述权利要求中任一项所述的镶板,其中,至少一个覆盖层包括金属箔。
22.根据前述权利要求中任一项所述的镶板,其中,至少一个覆盖层至少部分地由天然纤维制成。
23.根据前述权利要求中任一项所述的镶板,其中,所述发泡芯层包括至少一个支撑结构。
24.根据前述权利要求中任一项所述的镶板,其中,所述木质泡沫是开孔泡沫。
25.根据前述权利要求中任一项所述的镶板,其中,所述镶板包括多个发泡芯层,其中每个发泡芯层均包含木质泡沫。
26.根据前述权利要求中任一项所述的镶板,其中,至少一个发泡芯层的厚度为0.5cm至20cm,优选为1cm至15cm,更优选为2cm至10cm。
27.根据前述权利要求中任一项所述的镶板,其中,所述覆盖层具有至少800kg/m3、优选至少900kg/m3、更优选至少1000kg/m3的密度。
28.根据前述权利要求中任一项所述的镶板,其中,所述覆盖层的厚度为1mm至10mm,优选为2mm至7mm。
29.根据前述权利要求中任一项所述的镶板,其中,至少一个发泡芯层和至少一个覆盖层熔合在一起。
30.根据前述权利要求中任一项所述的镶板,其中,至少一个发泡芯层和至少一个覆盖层胶合在一起。
31.根据前述权利要求中任一项所述的镶板,其中,所述覆盖层的上表面积超过所述发泡芯层的上表面积。
32.根据前述权利要求中任一项所述的镶板,其中,所述镶板包括至少两个覆盖层,所述覆盖层都直接或间接地固定至所述至少一个发泡芯层的顶部的相对侧。
33.根据前述权利要求中任一项所述的镶板,其中,所述镶板包括至少一对、优选多对相对的侧边缘,所述侧边缘设置有互连的联接装置。
34.根据前述权利要求中任一项所述的镶板,其中,至少一个发泡芯层包含矿物材料,特别是胶结剂。
35.根据前述权利要求中任一项所述的镶板,其中,所述镶板的每一层都是基本防水的层。
36.根据前述权利要求中任一项所述的镶板,其中,所述镶板没有任何覆盖层。
37.根据前述权利要求中任一项所述的镶板,其中,所述镶板没有任何基于木质泡沫的发泡芯层。
38.根据前述权利要求中的一项所述的镶板,其中,至少一个镶板层包含和/或涂覆有至少一种抗微生物剂。
39.根据权利要求38所述的镶板,其中,所述抗微生物剂选自:(i)有机或有机金属抗微生物物质,例如卤代苯基醚、卤代水杨酰苯胺、倍半萜醇、卤代碳酰替苯胺、双酚化合物、一般酚类、甲醛、季铵化合物、吡啶衍生物以及六氯酚;和/或(ii)无机抗微生物物质,包括玻璃或陶瓷基质中的银、锌或铜,其中抗微生物剂优选包含2,4,4’-三氯-2’-羟基二苯醚。
40.一种绝缘覆盖物,特别是墙壁覆盖物或地板覆盖物,所述绝缘覆盖物包括多个根据权利要求1至39中任一项所述的绝缘镶板。
41.一种制造绝缘镶板的方法,所述绝缘镶板特别是墙壁镶板或屋顶镶板,优选是根据权利要求1至39中任一项所述的绝缘镶板,所述方法包括以下步骤:
a)提供包括上侧和下侧的至少一个发泡芯层,其中所述发泡芯层包含木质泡沫;
b)提供包括致密木材的至少一个装饰性覆盖层;以及
c)将至少一个覆盖层固定至所述发泡芯层的上侧和/或下侧。
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JP2023509208A (ja) | 2023-03-07 |
CA3163660A1 (en) | 2021-07-15 |
NL2024628B1 (en) | 2021-09-07 |
KR20220143022A (ko) | 2022-10-24 |
WO2021140242A1 (en) | 2021-07-15 |
BR112022013166A2 (pt) | 2022-09-13 |
AU2021205650A1 (en) | 2022-08-04 |
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US20230039750A1 (en) | 2023-02-09 |
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