EP2662192B1 - Bodenplatte und Herstellungsverfahren dafür - Google Patents
Bodenplatte und Herstellungsverfahren dafür Download PDFInfo
- Publication number
- EP2662192B1 EP2662192B1 EP12167099.6A EP12167099A EP2662192B1 EP 2662192 B1 EP2662192 B1 EP 2662192B1 EP 12167099 A EP12167099 A EP 12167099A EP 2662192 B1 EP2662192 B1 EP 2662192B1
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- EP
- European Patent Office
- Prior art keywords
- blocks
- floor panel
- wood
- equal
- layer
- 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.)
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- 238000000034 method Methods 0.000 title claims description 8
- 238000004519 manufacturing process Methods 0.000 title claims description 4
- 239000002023 wood Substances 0.000 claims description 102
- 239000000463 material Substances 0.000 claims description 53
- 239000010410 layer Substances 0.000 claims description 42
- 239000012792 core layer Substances 0.000 claims description 20
- 239000000835 fiber Substances 0.000 claims description 17
- 239000002861 polymer material Substances 0.000 claims description 9
- -1 polyethylene Polymers 0.000 claims description 6
- 239000000945 filler Substances 0.000 claims description 5
- 239000004698 Polyethylene Substances 0.000 claims description 3
- 239000004743 Polypropylene Substances 0.000 claims description 3
- 239000011248 coating agent Substances 0.000 claims description 3
- 238000000576 coating method Methods 0.000 claims description 3
- 238000005520 cutting process Methods 0.000 claims description 3
- 229920000573 polyethylene Polymers 0.000 claims description 3
- 229920001155 polypropylene Polymers 0.000 claims description 3
- 230000003014 reinforcing effect Effects 0.000 claims description 3
- 239000004794 expanded polystyrene Substances 0.000 claims description 2
- 239000004795 extruded polystyrene foam Substances 0.000 claims description 2
- 229920000642 polymer Polymers 0.000 description 21
- 230000000295 complement effect Effects 0.000 description 6
- 239000011094 fiberboard Substances 0.000 description 6
- 239000003292 glue Substances 0.000 description 6
- 229920002522 Wood fibre Polymers 0.000 description 5
- 239000000428 dust Substances 0.000 description 5
- 239000002245 particle Substances 0.000 description 5
- 239000006260 foam Substances 0.000 description 4
- 239000002025 wood fiber Substances 0.000 description 4
- 239000000654 additive Substances 0.000 description 3
- 239000011230 binding agent Substances 0.000 description 3
- 239000002131 composite material Substances 0.000 description 3
- 230000002787 reinforcement Effects 0.000 description 3
- 239000002344 surface layer Substances 0.000 description 3
- OYPRJOBELJOOCE-UHFFFAOYSA-N Calcium Chemical compound [Ca] OYPRJOBELJOOCE-UHFFFAOYSA-N 0.000 description 2
- 239000011575 calcium Substances 0.000 description 2
- 229910052791 calcium Inorganic materials 0.000 description 2
- 238000000748 compression moulding Methods 0.000 description 2
- 229910000514 dolomite Inorganic materials 0.000 description 2
- 239000010459 dolomite Substances 0.000 description 2
- 235000013312 flour Nutrition 0.000 description 2
- 239000004922 lacquer Substances 0.000 description 2
- 239000012764 mineral filler Substances 0.000 description 2
- 239000011120 plywood Substances 0.000 description 2
- 238000004381 surface treatment Methods 0.000 description 2
- 229920001187 thermosetting polymer Polymers 0.000 description 2
- JOYRKODLDBILNP-UHFFFAOYSA-N Ethyl urethane Chemical compound CCOC(N)=O JOYRKODLDBILNP-UHFFFAOYSA-N 0.000 description 1
- 229920002430 Fibre-reinforced plastic Polymers 0.000 description 1
- 229920000877 Melamine resin Polymers 0.000 description 1
- 239000004793 Polystyrene Substances 0.000 description 1
- XSQUKJJJFZCRTK-UHFFFAOYSA-N Urea Chemical compound NC(N)=O XSQUKJJJFZCRTK-UHFFFAOYSA-N 0.000 description 1
- NIXOWILDQLNWCW-UHFFFAOYSA-N acrylic acid group Chemical group C(C=C)(=O)O NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 description 1
- 230000003213 activating effect Effects 0.000 description 1
- 238000005452 bending Methods 0.000 description 1
- 239000004202 carbamide Substances 0.000 description 1
- 239000011093 chipboard Substances 0.000 description 1
- 230000001419 dependent effect Effects 0.000 description 1
- 229920001971 elastomer Polymers 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 239000011151 fibre-reinforced plastic Substances 0.000 description 1
- 210000001145 finger joint Anatomy 0.000 description 1
- 229920005570 flexible polymer Polymers 0.000 description 1
- 238000009408 flooring Methods 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 238000005304 joining Methods 0.000 description 1
- 239000011159 matrix material Substances 0.000 description 1
- JDSHMPZPIAZGSV-UHFFFAOYSA-N melamine Chemical compound NC1=NC(N)=NC(N)=N1 JDSHMPZPIAZGSV-UHFFFAOYSA-N 0.000 description 1
- 238000003801 milling Methods 0.000 description 1
- 238000000465 moulding Methods 0.000 description 1
- 239000003921 oil Substances 0.000 description 1
- 239000000123 paper Substances 0.000 description 1
- 230000000149 penetrating effect Effects 0.000 description 1
- ISWSIDIOOBJBQZ-UHFFFAOYSA-N phenol group Chemical group C1(=CC=CC=C1)O ISWSIDIOOBJBQZ-UHFFFAOYSA-N 0.000 description 1
- 229920006254 polymer film Polymers 0.000 description 1
- 229920000098 polyolefin Polymers 0.000 description 1
- 229920002223 polystyrene Polymers 0.000 description 1
- 229920002635 polyurethane Polymers 0.000 description 1
- 239000004814 polyurethane Substances 0.000 description 1
- 239000004800 polyvinyl chloride Substances 0.000 description 1
- 239000005060 rubber Substances 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 239000004634 thermosetting polymer Substances 0.000 description 1
- 210000002105 tongue Anatomy 0.000 description 1
- 238000002604 ultrasonography Methods 0.000 description 1
- 239000002966 varnish Substances 0.000 description 1
- 239000001993 wax Substances 0.000 description 1
Images
Classifications
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F15/00—Flooring
- E04F15/02—Flooring or floor layers composed of a number of similar elements
- E04F15/04—Flooring or floor layers composed of a number of similar elements only of wood or with a top layer of wood, e.g. with wooden or metal connecting members
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F15/00—Flooring
- E04F15/02—Flooring or floor layers composed of a number of similar elements
- E04F15/10—Flooring 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
Definitions
- the present disclosure relates to building panels and in particular to floor panels.
- parquet floor panels comprising a core which is formed of a plurality of low-grade wood blocks (also termed “slats” or “lamellae”, which are arranged with their fiber direction perpendicular to a longitudinal direction of the floor panel.
- the core is sandwiched between a decorative layer, typically of an about 3 mm wood surface layer, and a balancing layer, typically of an about 2 mm wood veneer.
- the decorative layer and the balancing layer are glued to the core.
- parquet floor panels examples include WO96/30177 A1 and US2005/0208255A1 . Further examples are provided in US2007/0292656A1 and US2004/0226243A1 .
- the present invention aims generally at overcoming or alleviating some disadvantages of prior art floor panels, with a particular focus on reduction of cost.
- a floor panel comprising a decorative layer and a core layer.
- the core is arranged below the decorative layer when the floor panel is substantially horizontally oriented.
- the core layer comprises a plurality of wood blocks arranged with their respective principal fiber directions substantially parallel with a plane defined by a major surface of the floor panel and substantially perpendicular to a principal direction of the floor panel.
- the core layer comprises a plurality of second material blocks, which are made from a different material than said wood blocks, and along the principal direction of the floor panel, the core layer presents alternating portions formed of said wood blocks and of said second material blocks.
- a "principal fiber direction” is defined as the direction along which most of the fibers of the wood block extend. Typically, the principal fiber direction substantially coincides with a longitudinal direction of the wood block since lumber is normally sawn so as to have its fibers extend substantially longitudinally.
- the "major surface” is typically the upwardly or downwardly surface of a floor panel. These surfaces are typically parallel with each other.
- a "principal direction" of the floor panel may be a longitudinal direction in a case where the floor panel is elongate (i.e. substantially rectangular and non-square).
- the principal direction may be a direction which is substantially parallel with a direction along which another layer, e.g. the decorative layer and/or the balancing layer, forming part of the floor panel, presents its major bending strength and/or major tensile strength, such as a principal fiber direction of the decorative layer and/or of the balancing layer.
- a "second material block” is understood as a block of material which is different from the material of the wood blocks.
- the second material blocks may e.g. be of generally lower quality (strength and/or stiffness) and/or cost than the wood blocks.
- the second material blocks mainly serve to fill the space between the wood blocks, and possibly to provide sound reduction.
- a floor panel comprising a plurality of second material blocks may be produced at reduced cost compared with a floor panel comprising only wood blocks, since such second material may be less costly than even the lowest quality wood.
- the second material may reduce weight of the floor panel as compared to a floor panel comprising only wood, thus reducing cost of transportation and facilitating installation.
- a total length of the second material blocks may be less than a total length of the wood blocks.
- a total length of the second material blocks may be more than 5%, preferably more than 10%, 20%, 30% or 40% of the total length of the floor panel. Typically, the total length of the second material blocks is less than 50% of the total length of the floor panel.
- the second material blocks have lower density than said wood blocks and/or lower tensile strength in a direction parallel to said principal fiber directions than said wood blocks.
- the second material blocks may comprise expanded polymer material blocks, such as at least one of expanded polyethylene, expanded polypropylene and expanded polystyrene extruded polystyrene foam.
- the second material blocks may comprise an engineered wood product.
- Non-limiting examples of engineered wood products include fiberboards, chip boards, particle boards, and reconstituted wood.
- the second material blocks may comprise a non-expanded polymer material comprising filler material.
- the wood blocks comprise, or consist essentially of, wood blocks of a wood quality, which is lower than or equal to V according to the Swedish "Gröna boken" ("The Green book") standard of 1960, preferably lower than or equal to VI or lower than or equal to VII.
- the wood blocks may be of a wood quality which is lower than or equal to B according to the Swedish "Bl ⁇ a boken” ("The Blue book") standard of 1994, preferably lower than or equal to C or lower than or equal to D.
- the wood blocks may comprise wood blocks of a quality which is lower than or equal to G4-2/G2-2 of the European EN 1611-1 standard of 2000, preferably lower than or equal to G4-3/G2-3 or lower than or equal to G4-4/G2-4.
- the wood blocks may also, or as an alternative, comprise, or consist essentially of, wood blocks of a strength class, which is lower than or equal to C18 of the EN 338 standard, preferably lower than or equal to C16 or lower than or equal to C14.
- wood blocks which are of low or very low quality, and hence cost, may be used to a great extent.
- the core layer may further comprise a reinforcing inset portion, which may be provided at a short side edge portion of the floor panel.
- the core layer of the floor panel may consist of about 80-99 % by volume, possibly 90-95 % by volume, of alternating wood and second material blocks.
- the remainder may consist of, inter alia, inset pieces, adapted to provide specific parts of the locking system.
- the second material blocks may be provided with surface coating at an edge portion where said second material blocks are exposed.
- the second material blocks may present a portion of increased density at an edge portion where said second material blocks are exposed.
- the decorative layer may comprise, or consist essentially of, natural wood.
- the floor panel comprises a balancing layer, and the core layer is sandwiched between the balancing layer and the decorative layer.
- a method of making a floor panel comprising arranging a plurality of elongate wood blocks side by side in a co-planar manner, with their respective longitudinal directions substantially parallel with each other to form a core layer.
- the method further comprises providing the core layer with at least a decorative layer to form a panel blank, and cutting the panel blank to form an elongate floor panel blank, such that the longitudinal directions of the wood blocks are substantially perpendicular to a principal direction of the floor panel blank.
- the method further comprises providing a plurality of second material blocks arranged alternatingly with the wood blocks along the principal direction of the floor panel blank.
- the second material blocks have lower density than said wood blocks and/or lower tensile strength in a direction parallel to said principal fiber directions than said wood blocks.
- the method may further comprise forming locking means along said principal direction of the floor panel blank.
- Fig. 1 is a schematic exploded view of a floor panel blank 1, comprising a decorative layer 13, a core layer 10, 11 and a balancing layer 12.
- Fig. 2 shows a floor panel blank 1' in an assembled state.
- the core layer 10, 11 is formed of wood blocks 10 and expanded polymer blocks 11, which are arranged alternatingly along a longitudinal direction L of the floor panel blank.
- this longitudinal direction of the floor panel blank may be substantially parallel with a principal fiber direction of a wood veneer forming a visually exposed upper surface of the decorative layer 13.
- the wood blocks 10 may be substantially elongate, with their respective principal fiber direction substantially coinciding with a respective longitudinal direction I of the respective block 10.
- a cross section of the wood blocks 10 may present a thickness Tw and a width Ww.
- the width Ww may be greater than the thickness Tw.
- the longitudinal direction I of the wood blocks 10 may extend 90° ⁇ 45° relative to the longitudinal direction L of the floor panel blank.
- the wood blocks extend 90° ⁇ 30°, 90° ⁇ 15°, 90° ⁇ 5° or 90° ⁇ 1° relative to the longitudinal direction of the panel blank.
- the wood blocks comprise blocks of any appearance, and for cost reasons, the wood blocks comprise, or consist essentially of, (e.g. consist of at least 50%, at least 70 %, at least 90% or at least 95%) a wood quality lower than or equal to V according to the Swedish "Gröna boken" ("The Green book") standard of 1960, preferably lower than or equal to VI or lower than or equal to VII; lower than or equal to B according to the Swedish "Bl ⁇ a boken” ("The Blue book”) standard of 1994, preferably lower than or equal to C or lower than or equal to D; or lower than or equal to G4-2/G2/2 of the European EN 1611-1 standard of 2000, preferably lower than or equal to G4-3/G2-3 or lower than or equal to G4-4/G2-4.
- the wood is of quality V or VI according to the "Gröna boken” standard, or of a corresponding quality according to any other standard.
- the wood blocks may have a strength class lower than or equal to C18 of the EN 338 standard, preferably lower than or equal to C16 or lower than or equal to C14.
- the wood blocks may be formed of elongate wood beams, and/or of shorter pieces of wood which have been joined together (e.g. using finger joints, dovetail joints and/or glue).
- the expanded polymer blocks 11 may be so-called "rigid polymer foams", which may be defined as foams that have a modulus of elasticity (E) of about 0.02 - 0.4 GPa, preferably of about 0.1-0.4 GPa.
- the density may be in the area of 20-400 kg/m 3 , preferably about 10-100 kg/m 3 , most preferably about 20-50 kg/m 3 .
- the expanded polymer blocks 11 may be, or comprise, so-called "flexible polymer foams", which may be defined as foams that have a modulus of elasticity (E) of about 0.0003 - 0.0015 GPa.
- E modulus of elasticity
- the density may be in the area of 5-200 kg/m 3 .
- the expanded polymer blocks 11 may be so-called closed cell expanded polymer or open cell expanded polymer.
- materials include polystyrene, polyurethane, polyolefin (e.g. polyethylene, polypropylene), thermosets (phenolic, melamine, urea or combinations thereof) and polyvinyl chloride (PVC).
- polystyrene polyurethane
- polyolefin e.g. polyethylene, polypropylene
- thermosets phenolic, melamine, urea or combinations thereof
- PVC polyvinyl chloride
- the expanded polymer material blocks may comprise additives, such as wood chips, wood particles, wood dust (saw dust, wood flour) or wood fibers; mineral fillers (calcium, dolomite, etc); polymeric fillers (e.g. chunks or particles of recycled polymers, rubbers or rubber-like materials).
- the expanded polymer blocks may have such properties as to allow them to be formed by cutting in connection with the forming of the locking system.
- the expanded polymer blocks 11 are illustrated as being substantially elongate, with their respective longitudinal direction parallel with the longitudinal directions I of the wood blocks 10.
- a cross section of the expanded polymer blocks 11 may present a thickness Tp and a width Wp.
- the width Wp may be greater than the thickness Tp.
- the thickness Tw of the wood blocks may typically be on the order of about 5-50 mm, more commonly about 5-25 mm or about 7-15 mm, and most typically about 10 mm.
- the thickness Tw of the wood blocks 10 may be substantially the same, or exactly the same, as the thickness Tp of the expanded polymer blocks 11.
- the width Ww of the wood blocks 10 may be greater than the width Wp of the expanded polymer blocks 11.
- the width Wp of the expanded polymer blocks 11 may be less than about 90%, less than about 80%, less than about 70% or less than about 60% of the width Ww of the wood blocks 10.
- the floor panel 1" may thus have a core formed of alternating wood and expanded polymer blocks along substantially its entire length, optionally with the exception of one or both short side edges, which may be provided with a reinforcing inset, which may be formed of wood of a higher quality than that of the wood blocks 10, a different type of wood, and/or of wood having a different fiber direction, e.g. perpendicular to, that of the wood blocks 10.
- the insets may be formed of another material, such as MDF, HDF, polymer or polymer composite (e.g. fiber reinforced polymer).
- Each of the insets may extend over less than 15% of the floor panel's 1" length, preferably less than 10%, less than 5% or less than 3% of the floor panel's 1" length.
- Such insets may, additionally, or as a complement, be provided for one or both long side edges, in which case the insets would extend along all or part of the long side edge(s), and perpendicular to the principal direction of the floor panel.
- the floor panel 1" may be provided with a locking system 30, 31, 32, 33 adapted for interconnection of the floor panel 1" with similar or identical floor panels.
- a locking system may be arranged to provide mechanical or form-fit locking horizontally and/or vertically, i.e. the floor panels may be locked together wholly or partially without the use of glue.
- the long side locking system 30, 31 may be identical with the short side locking system 32, 33. In another embodiment, the long side locking system 30, 31 may be different from that of the short side locking system in terms of e.g. geometry and/or mechanical properties of the locking system.
- a plurality of different systems for mechanical interconnection of floorboards are known as such, and so are the methods of producing them.
- Non-limiting examples of such systems are shown in WO94/26999A1 US4,426,820 , DE1211175 , DE19851200C1 , FR2675174 , WO99/66151 , WO97/47834 , JP3169967 , WO96/27721 , GB1430423 , WO02/55809 , US4,819,932 , EP1863984A1 and EP1802827A1 , the entire contents of which documents are hereby incorporated herein by reference.
- a method of producing a floor panel 1" is disclosed.
- Pre-cut blocks 10 of wood as well as pre-formed (e.g. cut or moulded) blocks 11 of expanded polymer may be arranged on a first sheet, which may be the balancing layer 12 or the decorative layer 13.
- the first sheet 12, 13 and/or the side of the blocks 10, 11 facing the first sheet may be provided with glue prior to the joining of the blocks 10, 11 to the first sheet 12.
- a second sheet 13 is provided and its side facing the blocks 10, 11 and/or the side of the blocks 10, 11 facing the second sheet are provided with glue, after which the second sheet 13 is joined with the blocks.
- the blocks 10, 11 may be arranged so as to abut each other along their longitudinal direction I.
- a small space in the longitudinal direction L of the floor panel may be provided between the members of each pair of adjacent blocks.
- the space may be in the order of 0.1-5 mm, preferably 1-3 mm.
- the sheets 12, 13 and blocks 10, 11 may be subjected to pressure, either batchwise or continuously, e.g. by rollers or a belt press.
- the pressure may be complemented with addition of heat or other means for activating the glue, such as ultrasound, microwaves, etc..
- these steps are performed to provide a blank, which may have a size of on the order of about e.g. 1.2 m x 2.4 m.
- This blank may then be cut into floor panel blanks 1', i.e. blanks having the general shape of the finished floor panel 1 ", but without any locking system 30, 31, 32, 33 formed along its edges.
- the floor panel blanks 1' may then be subjected to milling and optionally addition of separate elements (locking tongues, locking elements, locking strips, etc.) to provide the desired locking system 30, 31, 32,33.
- the decorative layer 13 may be in the form of a solid wood sheet, which typically has a thickness of about 2-5 mm, most often about 3 mm.
- the wood sheet may be composed of a single or few wood blocks, or of a plurality of lamellae to form a block pattern on the surface. Typically most, or at least some, of these lamellae are elongate and extend substantially parallel to the longitudinal direction L of the floor panel. Alternatively, some of the lamellae extend perpendicular to the longitudinal direction L of the floor panel, as would be the case with floor panels for providing a so-called Dutch floor pattern.
- the decorative layer may be formed of a plurality of layers, such as e.g. a reinforcement layer combined with a thin surface layer, which is laminated or glued to the reinforcement layer.
- the surface layer may be formed of e.g. a thin (0.5-2 mm) wood veneer, or a laminate, i.e. an artificially patterned (e.g. printed) layer, which may be laminated to, or integrated with, a wear layer, which may comprise a polymer material with fillers and additives for providing a hard surface.
- the reinforcement layer may be formed of plywood, MDF, HDF or other sheet material.
- a decorative layer 13 of wood or wood veneer may be natural, i.e. uncoated, or coated/treated with e.g. lacquer, wax, oil, varnish or any other type of surface finish, such as acrylic or urethane based floor finishes.
- the balancing layer 12 may be formed of a thin (0.5-2 mm) sheet of wood or plywood.
- the balancing layer may be formed of a polymer film, a woven or non-woven sheet, a pulp-based material (such as paper) or other wood-polymer composite material.
- the floor panel typically forms part of a set of substantially identical floor panels, which are to be joined together to provide a flooring.
- the expanded polymer blocks referred to above may be replaced or complemented with blocks of another material, which may be less costly, have lower density and/or lower tensile strength in the direction which is parallel with the principal direction of the wood fibers of the wood blocks.
- the second material blocks may comprise an engineered wood product.
- a first example of such a material is a so-called LDF (low density fiberboard) or VLDF (very low density fiberboard), which may be a board which is formed through moulding or compression moulding of wood chips, particles and/or dust. It is possible to mould such material during wet or moist condition, in which no or very little additional binder need to be added.
- LDF low density fiberboard
- VLDF very low density fiberboard
- an LDF board may be used having a density of 160-500 kg/m 3 may be used.
- VLDF board may be used having a density of 200-300 kg/m 3 .
- LDF and VLDF boards are known from Rowell, R. et al: “Dimensionally Stabilized Very Low Density Fiberboard", Wood and Fiber Science, 27(4). pp. 428-436 (1995 ), the entire content of which is hereby incorporated herein by reference.
- a ULDF (ultra low density fiber) board may be used having a density of 50-200 kg/m 3 .
- Such fiber boards are known through Xie, Y. et al: "Manufacture and Properties of Ultra-Low Density foamed Fibreboard from Wood Fibre", BioResources 6(4), 4055-4066 (2011 ) the entire content of which is hereby incorporated herein by reference.
- fiber boards having low, very low or ultra low density may be provided substantially without binder (wet/moist compression moulding), with binder and/or with additional additives.
- non-expanded composite polymer material blocks comprising a polymer matrix and fillers, such as e.g. wood chips, wood particles, wood dust (saw dust, wood flour) or wood fibers, mineral fillers (calcium, dolomite, etc).
- fillers such as e.g. wood chips, wood particles, wood dust (saw dust, wood flour) or wood fibers, mineral fillers (calcium, dolomite, etc).
- Exposed portions of second material blocks of wood fiber (e.g. LDF, VLDF, ULDF) or filled polymer material may also be provided with surface treatment in order to improve e.g. strength, friction (reduce) or wear properties.
- Such treatment may include the application of penetrating or coating forming matter, such as lacquer and/or thermosetting polymers.
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- Engineering & Computer Science (AREA)
- Architecture (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Life Sciences & Earth Sciences (AREA)
- Wood Science & Technology (AREA)
- Floor Finish (AREA)
Claims (13)
- Bodenplatte, welche Folgendes umfasst:eine Dekorschicht (13), undeine Kernschicht (10, 11), die unter der Dekorschicht (13) angeordnet ist, wenn die Bodenplatte im Wesentlichen waagerecht ausgerichtet ist, undeine Ausgleichsschicht, wobei die Kernschicht zwischen der Ausgleichsschicht und der Dekorschicht angeordnet ist,wobei die Kernschicht mehrere Holzblöcke (10), die mit ihren entsprechenden Hauptfaserrichtungen im Wesentlichen parallel zu einer Ebene (So), die durch eine Hauptoberfläche der Bodenplatte definiert ist, und im Wesentlichen senkrecht zu einer Hauptrichtung (L) der Bodenplatte angeordnet sind, undmehrere zweite Materialblöcke (11), die aus einem unterschiedlichen Material als die Holzblöcke (10) hergestellt sind, umfasst,dadurch gekennzeichnet, dassentlang der Hauptrichtung (L) der Bodenplatte, die Kernschicht abwechselnde Abschnitte gebildet aus den Holzblöcken (10) und den zweiten Materialblöcken (11) aufweist,die zweiten Materialblöcke (11) eine geringere Dichte als die Holzblöcke (10) und/oder eine geringere Zugfestigkeit in einer Richtung parallel zu der Hauptfaserrichtung als die Holzblöcke (10) aufweisen,die Holzblöcke (10) Holzblöcke einer Holzqualität umfassen, welche Folgendes ist:geringer als oder gleich V gemäß des schwedischen Standards "Gröna boken" ("Das Grüne Buch") von 1960, vorzugsweise geringer als oder gleich VI oder geringer als oder gleich VII;geringer als oder gleich B gemäß des schwedischen Standards "Blåa boken" ("Das Blaue Buch") von 1994, vorzugsweise geringer als oder gleich C oder geringer als oder gleich D; und/odergeringer als oder gleich G4-2/G2-2 der europäischen Norm EN 1611-1 von 2000, vorzugsweise geringer als oder gleich G4-3/G2-3 oder geringer als oder gleich G4-4/G2-4.
- Bodenplatte nach Anspruch 1, wobei, entlang der Hauptrichtung (L) der Bodenplatte, eine Gesamtlänge der zweiten Materialblöcke (11) geringer als eine Gesamtlänge der Holzblöcke (10) ist.
- Bodenplatte nach Anspruch 1 oder 2, wobei, entlang der Hauptrichtung (L) der Bodenplatte, eine Gesamtlänge der expandierten zweiten Materialblöcke (11) höher als 5 %, vorzugsweise höher als 10 %, 20 %, 30 % oder 40 % einer Gesamtlänge der Bodenplatte ist.
- Bodenplatte nach einem der vorhergehenden Ansprüche, wobei die zweiten Materialblöcke Materialblöcke aus expandiertem Polymer umfassen, wie zum Beispiel mindestens entweder expandiertes Polyethylen, expandiertes Polypropylen oder extrudierter Polystyrolschaum aus expandiertem Polystyrol.
- Bodenplatte nach einem der vorhergehenden Ansprüche, wobei die zweiten Materialblöcke ein Holzwerkstoffprodukt umfassen.
- Bodenplatte nach einem der vorhergehenden Ansprüche, wobei die zweiten Materialblöcke ein nicht-expandiertes Polymermaterial, das einen Füllstoff umfasst, umfassen.
- Bodenplatte nach einem der vorhergehenden Ansprüche, wobei die Kernschicht ferner einen verstärkenden Einsatzabschnitt umfasst.
- Bodenplatte nach einem der vorhergehenden Ansprüche, wobei die zweiten Materialblöcke (11) mit einer Oberflächenbeschichtung an einem Kantenabschnitt versehen sind, an welchem die zweiten Materialblöcke freiliegen.
- Bodenplatte nach einem der vorhergehenden Ansprüche, wobei die zweiten Materialblöcke (11) einen Abschnitt erhöhter Dichte an einem Kantenabschnitt aufweisen, an welchem die zweiten Materialblöcke freiliegen.
- Bodenplatte nach einem der vorhergehenden Ansprüche, wobei die Dekorschicht (13) Holz umfasst.
- Bodenplatte nach einem der vorhergehenden Ansprüche, wobei eine Dicke (Tw) der Holzblöcke (10) im Wesentlichen die gleiche oder exakt die gleiche wie eine Dicke (Tp) der zweiten Materialblöcke (11) ist.
- Verfahren zur Herstellung einer Bodenplatte, welches Folgendes umfasst:das Anordnen mehrerer länglicher Holzblöcke (10) nebeneinander in einer komplanaren Art und Weise, mit ihren entsprechenden Längsrichtungen (I) im Wesentlichen parallel zueinander, zum Bilden einer Kernschicht,das Versehen der Kernschicht mit mindestens einer Dekorschicht (13) zum Bilden eines Plattenrohlings,das Versehen der Kernschicht mit einer Ausgleichsschicht, derart, dass die Kernschicht zwischen der Ausgleichsschicht und der Dekorschicht angeordnet ist,das Schneiden des Plattenrohlings zum Bilden eines länglichen Bodenplattenrohlings, derart, dass die Längsrichtungen (I) der Holzblöcke im Wesentlichen senkrecht zu einer Hauptrichtung (L) des Bodenplattenrohlings sind,gekennzeichnet durchdas Bereitstellen mehrerer zweiter Materialblöcke (11), die abwechselnd mit den Holzblöcken (10) entlang der Hauptrichtung (L) des Bodenplattenrohlings angeordnet sind,wobei die zweiten Materialblöcke eine geringere Dichte als die Holzblöcke und/oder eine geringere Zugfestigkeit in einer Richtung parallel zu den Hauptfaserrichtungen als die Holzblöcke (10) aufweisen,die Holzblöcke (10) Holzblöcke einer Holzqualität umfassen, welche Folgendes ist:geringer als oder gleich V gemäß des schwedischen Standards "Gröna boken" ("Das Grüne Buch") von 1960, vorzugsweise geringer als oder gleich VI oder geringer als oder gleich VII;geringer als oder gleich B gemäß des schwedischen Standards "Blåa boken" ("Das Blaue Buch") von 1994, vorzugsweise geringer als oder gleich C oder geringer als oder gleich D; und/oder geringer als oder gleich G4-2/G2-2 der europäischen Norm EN 1611-1 von 2000, vorzugsweise geringer als oder gleich G4-3/G2-3 oder geringer als oder gleich G4-4/G2-4.
- Verfahren nach Anspruch 12, welches ferner das Bilden von Verriegelungsmitteln (30, 31) entlang der Hauptrichtung (L) des Bodenplattenrohlings umfasst.
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US20210396025A1 (en) * | 2020-06-17 | 2021-12-23 | Praters Incorporated | Modular flooring system and subfloor assembly |
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