JP6026647B2 - Core, panel blank, floor panel and manufacturing method thereof - Google Patents

Description

  The present disclosure relates to building panels, particularly floor panels. More specifically, the present disclosure includes, for example, a core included in a building panel such as a floor panel, a blank for forming a building panel, and such a core, blank, and building panel. On how to do.

  Known as a parquet floor panel (also called slats or lamellae), which includes a core formed by multiple low-grade wood blocks and arranged so that the fiber direction is perpendicular to its longitudinal direction. It has been. The core is usually sandwiched between a decorative layer, which is a wood surface layer of about 3 mm, and a balance layer, usually a wood veneer of about 2 mm. The decorative layer and the balance layer are in close contact with the core.

  As mentioned above, floor panels have been manufactured since the 1940s, and apart from improvements in surface treatment, the introduction of adhesive technology and mechanical joining systems has changed little.

  Examples of parquet floor panels are disclosed, for example, in WO96 / 30177A1 and US2005 / 0208255A1.

  It would be desirable to further reduce the floor panel costs mentioned above.

International Publication No. 1996/30177 US Patent Application Publication No. 2005/0208255

  A “panel blank” is understood as a piece of material having substantially the same configuration as the final product, but is not complete with respect to, for example, the structure of the joining system at the end of the panel blank.

  A “blank” can be understood as a piece of material intended to be divided into a plurality of panel blanks.

  The “main surface” is usually the upper surface or the lower surface of the core, blank, panel blank, building panel, or floor panel. These planes are usually parallel to each other.

  The “main direction” of a core, blank, panel blank, building panel or floor panel may be the longitudinal direction if it is elongated (ie, not substantially rectangular and square). In other options or supplements, the main direction is a layer that is different from the core layer, for example, a blank, a panel blank or at least one of a decorative layer and a balance layer that forms part of a floor panel. It may be a direction showing at least one of strength and tensile strength, for example, a direction substantially parallel to the main fiber direction of at least one of the decorative layer and the balance layer.

  “Main fiber direction” is defined as the direction in which many of the wood block or veneer fibers extend. Since wood is usually cut so that its fibers extend substantially in the longitudinal direction, the main fiber direction substantially coincides with the longitudinal direction of the wood block.

  “Foamed polymer material” is understood as a polymer material comprising a resin and a substantial amount of inclusions filled with gas.

  The present invention broadly aims to overcome or alleviate some of the disadvantages of the prior art of floor panels and focuses on cost reduction.

  The invention is defined by the appended independent claims together with the dependent claims and the associated description, embodiments illustrated by the drawings.

According to the 1st form, the core contained in a building panel is provided. The core has a set of substantially parallel major surfaces. The core extends between the main surfaces, is disposed in each main direction substantially parallel to the main surface, and extends in a direction of 90 ° ± 45 ° with respect to the main direction of the core. A first block member, and a plurality of second block members extending between the main surfaces and arranged alternately with the first block member in the main direction of the core. The first block material and the second block material are substantially different with respect to at least one material property.
Such a core provides an opportunity to improve control over the properties and cost of the core, such as strength and weight, for example.

  The “main direction of the core” may be understood as the longitudinal direction of the core, and is specifically applicable when the core is produced as an elongated or substantially continuous sheet-like product.

  The first block material preferably extends 90 ° ± 30 °, 90 ° ± 15 °, 90 ° ± 5 ° or substantially perpendicular to the main direction of the core. The second block material will typically extend substantially parallel to the first block material.

  A “substantial difference” is a difference that goes beyond mere accidental variations due to block materials of the same type and orientation, for example, between two pieces of the same type of wood, or due to manufacturing tolerances, etc. means.

  The core may have a thickness of about 5 mm to about 50 mm, preferably about 7 mm to about 15 mm, between its major surfaces.

  The cross section perpendicular to the main surface of the core and along the main direction includes the same number of the entire first block material and the entire second block, and the cross section of the second block material. Indicates that the area is less than 50%.

  Therefore, the first block material occupies 50% or more of the volume of the core not including the end reinforcing portion.

  The core includes at least one web attached to at least one of the major surfaces and substantially covering at least one of the major surfaces.

  The web may include at least one of a nonwoven material, a woven material, a pulp-based material, and a polymer film.

  The web may include a material having an adhesive property to at least one of the first block and the second block.

  The web is flexible and the angle between the normals of the principal faces of a set of adjacent first block members is greater than 5 °, preferably greater than 10 °, 15 °, 20 ° or 25 °. Allows bending of the core.

  The first block material and the second block material are formed using different materials in at least one of material type, composition, density, hardness, tensile strength, and elastic modulus.

  With respect to “material types”, the blocks may be formed from different materials, such as wood and foamed polymer materials, or different types of polymer materials or different types of wood.

  With regard to “material composition”, the block may be formed from at least one of polymeric materials having different compositions and polymeric materials containing different types of fillers or additives.

  Regarding the material density, the first block material may be denser than the second block material.

  Regarding the “material hardness”, the first block material may be harder than the second block material.

  Regarding “orientation of the material”, the first block material and the second block material may have anisotropy or may be directed in different directions. For example, the first block material has fibers extending substantially perpendicular to the main direction of the core. On the other hand, the second block material extends substantially parallel to the main direction of the core or parallel to the thickness direction of the core.

  Regarding the “tensile strength of the material”, the first block material may have a higher tensile strength than the second block material.

  With regard to “material elastic modulus”, the first and second materials may exhibit different bending stiffnesses. Such bending stiffness will usually be shown at least with respect to the longitudinal direction of the block material.

  The main direction of the first block material may be substantially parallel to the main bending rigidity and / or the main tensile strength direction of the first block material.

In one set of embodiments, the first block material may be formed from a wood material.
And the said main direction of a said 1st block material may be substantially parallel to the main direction of the fiber of the said wooden material.

  The wood block may include a wood block of V or less, preferably VI or less or VII or less of the Swedish 1960 Grona boken (The Green book) standard. As another option, the wood block may be wood below B, preferably below C or below D according to the 1994 Swedish Blaa boken (The Blue book) standard. As a further option, the wood block may be G4-2 / G2-2 or less, preferably G4-3 / G2-3 or less, or G4-4 / G2-4 or less of the 2000 European EN1611-1 standard. May contain quality blocks.

  Preferably, the wood may be of V or VI quality according to the Grrna boken standard, or other standard corresponding quality.

  The wood block may be an EN 338 standard C18 or lower, preferably C16 or lower, or C14 or lower strength class, or alternatively, these strength classes.

  In another set of the embodiments, the first block material may be a composite material.

  The composite material may include a polymer material as a base material and include at least one of a filler and a reinforcing material.

  The filler may include wood powder, wood fiber, wood particles, wood chips, mineral filler or polymer material.

  The reinforcing material may be arranged to give anisotropic strength characteristics to the composite material.

  For example, the reinforcing material may include an elongated fiber extending substantially parallel to the main direction of the first block material. Therefore, the first block material may be formed from an artificial wood material.

  Non-limiting examples of artificial wood materials include fiberboard, chipboard, particleboard and reclaimed wood. It is possible to form the first block material and the second block material from different types of artificial wood materials.

  The second block material may be formed of a foamed polymer material, an artificial wood material, or a non-foamed polymer material. The expanded polymer block material (hereinafter referred to as expanded polymer block material) may include at least one of expanded polyethylene, expanded polypropylene, and expanded polystyrene obtained by extruding a polystyrene foam.

  The foamed polymer material may not include a filler, and may include, for example, a filler in the form of at least one of wood powder, wood fiber, wood particles, wood chips, a mineral filler, and a polymer material. .

  Usually, the second block material is formed of an artificial wood material that is at least one of lower cost, lower strength, and lower density than the first block material.

  Typically, the non-foamed polymer material comprises one or more polymer substrates and wood powder, wood fibers, wood particles, wood chips that are lower in cost or strength, or both, than the first block material. And a filler formed from at least one of a mineral filler and a polymer material. The density may be low or high. Low density is dominant in weight, and high density is desirable in sound absorption or attenuation characteristics. A 2nd form provides the blank for forming the building panel containing said core, and the at least 1 structure layer which substantially covers at least 1 of the main surface of the said core.

  The building panel may be a floor panel, a wall panel, a ceiling panel or a roof panel as a non-limiting example.

  The structural layer may include at least one of a decorative layer and a wear layer.

  The structural layer may further include a reinforcing layer disposed between the core and the decorative layer.

  In one set of embodiments, the decorative layer may include a laminate.

  In another set of embodiments, the decorative layer may include wood.

  In another set of embodiments, the decorative layer may comprise, for example, a plastic material such as polyvinyl chloride, acrylic, epoxy, polyurethane, a material such as rubber or rubber, or linoleum, or basically You may comprise from these.

  In some embodiments, the decorative layer may be formed of essentially solid wood material.

  The blank may further include a balance layer including at least one of a wood veneer, a polymer film, a woven fabric, a nonwoven fabric, and a pulp-based material.

  The main direction of the core may be substantially parallel to a direction of at least one main bending stiffness of the structural layer.

  The main direction of the core may be substantially parallel to the longitudinal direction of the blank.

  According to the 3rd form, the building panel formed from the blank as mentioned above is provided. Such floor panels may include a joining system along at least two of the opposite ends.

  According to a fourth aspect, there is provided a method of making a core for a building panel, the core having a set of substantially parallel major surfaces. The method provides a plurality of first block members, each main direction of the plurality of first block members being substantially parallel to the main surface and substantially perpendicular to the main direction of the core. The plurality of first block members are arranged so that the second block members are arranged alternately with the first block members in the main direction of the core.

  The step of providing the second block material may include disposing second preformed block materials alternately with the first block material.

  The step of providing the second block material may include supplying a polymer resin to a space that longitudinally separates the two first block materials and subsequently spreading the polymer resin.

  The step of providing the second block material may include at least initially supplying the second block material that is thicker than the first block material.

  The method may further comprise pressurizing the second block material with respect to applying a web or structural layer to the core.

  The method may further comprise using the second block material to provide adhesion between the core and the layer.

  According to a fifth aspect, there is provided a method of making a building panel, the method giving the above blank and in a form suitable for providing a building panel, the blank along the main direction of the core. Cutting the building panel blank and forming mechanical joining means along at least one end of the floor panel blank.

  The method may further comprise subjecting at least a part of the mechanical joining means to a surface treatment.

  As another or additional means, the surface treatment may include applying a coating to the exposed portion of the second block material.

  As another or additional means, the surface treatment may include thermoforming an exposed portion of the second block material.

  According to the sixth aspect, a floor panel including a decorative layer and a core layer is provided. When the floor panel is substantially horizontally oriented, the core is disposed under the decorative layer. The core layer includes a plurality of wood blocks, and a main fiber direction of each block is substantially parallel to a surface defined by a main surface of the floor panel and substantially in a main direction of the floor panel. Vertical. The core layer includes a plurality of second block members made of a material different from the wood block, and the core layer includes the wood block and the second block along the main direction of the floor panel. It includes portions where the block materials are alternately arranged.

  The “second block material” is understood as a block of material different from the material of the wood block. The second block material may be, for example, generally lower quality (at least one of strength and rigidity) and / or lower cost than the wood block. That is, the second block material mainly serves to fill a space between the wooden blocks, and enables sound reduction.

  Such a second material is less expensive than the lowest quality wood, and a floor panel comprising a plurality of second block materials can be produced at a lower cost than a floor panel comprising only wood blocks. .

  Further, the second material can reduce the weight of the floor panel as compared with a floor panel including only wood, reduce transportation costs, and facilitate installation.

  Along the main direction of the floor panel, the total length of the second block material is shorter than the total length of the wood block.

  Along the main direction of the floor panel, the total length of the second block material may exceed 5%, preferably 10%, 20%, 30% or 40% of the total length of the floor panel. Usually, the total length of the second block material is less than 50% of the total length of the floor panel.

  The second block material may have a lower density than the wood block, or a tensile strength in a direction parallel to the main fiber direction may be lower than the wood block, or both.

  The second block material may include, for example, a foamed polymer block material such as foamed polyethylene, foamed polypropylene, and foamed polystyrene obtained by extruding styrene foam.

  Optionally or complementarily, the second block material may comprise an artificial wood product.

  As yet another option or supplement, the second block material may include a non-foamed polymer material including a filler.

  Said wood blocks may comprise or basically consist of wood blocks which are below V, preferably below VI or below VII of the 1960 Swedish Grona boken (The Green book) standard. . As another option, the wood block may be wood below B, preferably below C or below D according to the Swedish Blaa boken (The Blue book) standard of 1994. As yet another option, the wood block is G4-2 / G2-2 or less, preferably G4-3 / G2-3 or less, or G4-4 / G2-4 or less of the 2000 European EN1611-1 standard. It may also contain wood blocks that are

  The wood block may include a wood block of an intensity class of C18 or less, preferably C16 or less or C14 or less of EN338 standard, or may be basically configured.

  And low quality, low cost, or rather low quality, low cost wood blocks will be widely used.

  The core layer may further include a reinforcing inset portion provided on a short side portion of the floor panel.

  Typically, the core layer of the floor panel is composed of alternating wood and second block material that occupy about 80-99% of the volume, preferably 90-95% of the volume. The remaining part consists of an inset, for example, adapted to provide a specific part of the joining system.

  The second block material may have a surface coating at an end portion where the second block material is exposed.

  Alternatively or complementarily, the second block material may have a portion having a high density at an end portion where the second block material is exposed.

  The decorative layer may include natural wood or may be basically composed of natural wood.

  The floor panel may include a balance layer, and the core layer may be sandwiched between the balance layer and the decorative layer.

  According to a seventh aspect, a method for making a floor panel is provided. In the method, in order to form the core layer, a plurality of elongated wooden blocks are arranged side by side so that their longitudinal directions are substantially parallel in the same plane. The method further includes providing the core layer with at least one decorative layer for forming a panel blank to form an elongated floor panel blank in which the longitudinal direction of the wood block is substantially perpendicular to its main direction. For this purpose, the panel blank is cut. The method further includes a plurality of second block members arranged alternately with the wood blocks along the main direction of the floor panel blank. The second block material has a lower density than the wood block, or a tensile strength in a direction parallel to the main fiber direction is lower than the wood block, or both.

  The method further forms locking means along the main direction of the floor panel blank.

It is a typical exploded view of a panel blank. It is a typical perspective view of a panel blank. It is a typical perspective view of a part of floor panel. It is a model top view of a floor panel. It is a schematic cross section of a floor panel. (A)-(c) shows a manufacturing method of a blank or a panel blank typically. (A)-(d) shows typically the 1st modification of the manufacturing method of a blank or a panel blank. (A) And (b) shows the 2nd modification of a manufacturing method of a blank or a panel blank typically. (A)-(c) shows a core typically. The 3rd modification of the manufacturing method of a blank or a panel blank is typically shown.

  FIG. 1 is a schematic exploded view of a floor panel blank 1 including a decorative layer 13, core layers 10 and 11, and a balance layer 12. FIG. 2 shows the floor panel blank 1 ′ in the assembled state. The core layers 10 and 11 are formed of the wood block 10 and the foamed polymer block 11 and are alternately arranged along the longitudinal direction L of the floor panel blank. For example, the longitudinal direction of the floor panel blank may be substantially parallel to the main fiber direction of the wood veneer that forms the visually exposed top surface of the decorative layer 13.

  The wood block 10 may be substantially elongated and have a respective primary fiber direction that substantially coincides with the longitudinal direction I of each block 10. The cross section of the wood block 10 has a thickness Tw and a width Ww. The width Ww may be wider than the thickness Tw.

  The longitudinal direction I of the wood block 10 extends in the direction of 90 ° ± 45 ° with respect to the longitudinal direction L of the floor panel blank. Preferably, the wood block extends in the range of 90 ° ± 30 °, 90 ° ± 15 °, 90 ° ± 5 ° or 90 ° ± 1 ° with respect to the longitudinal direction of the panel blank.

  The wooden block may include a block having an arbitrary shape. However, in terms of cost, the wooden block is V or less, preferably VI or less, or VII or less, 1994 or less of the Swedish Grona boken (The Green book) standard of 1960, 1994. B or less in the Swedish Blaa boken (The Blue book) standard of the year, preferably C or less or D or less, or G4-2 / G2 / 2 or less in the 2000 European EN1611-1 standard, preferably G4-3 / Contain G3-3 or less, or G4-4 / G2-4 or less, or basically consist of at least 50%, at least 70%, at least 90%, or at least 95%, for example Is preferred.

  Further, the wood block may have an EN 338 standard C18 or less, preferably C16 or less or C14 or less strength class.

  The wood block may be an elongated wood beam, a collection of short pieces of wood, or both. The aggregate of pieces of wood is joined using, for example, at least one of a finger joint, a dovetail joint, and an adhesive.

  The foamed polymer block 11 is a so-called “hard polymer foam” and can be defined as a foam having an elastic modulus (E) of about 0.02-0.4 GPa, preferably about 0.1-0.4 GPa. Its density is in the range of 20-400 kg / m3, preferably about 10-100 kg / m3, most preferably about 20-50 kg / m3.

  As an option, the foamed polymer block 11 is a so-called “plastic polymer foam”, which can be defined as a foam having an elastic modulus (E) of about 0.0003-0.0015 GPa. The density may be in the range of 5-200 kg / m3.

  The foamed polymer block 11 may be a so-called closed cell foam polymer or open cell foam polymer.

  Examples of materials include polystyrene, polyurethane, polyolefins (eg, polyethylene, polypropylene), thermosetting resins (phenol, melamine, urea or mixtures thereof) and polyvinyl chloride (PVC).

  Foamed polymer block materials include, for example, wood chips, wood particles, wood powder (cutting chips, wood flour) or wood fiber additives, mineral fillers (calcium, dolomite, etc.), polymer fillers (eg recycled) Polymer, rubber or materials such as rubber). The foamed polymer block 11 is substantially elongated and has a longitudinal direction parallel to the longitudinal direction I of the wood block 10. The cross section of the foamed polymer block 11 has a thickness Tp and a width Wp. The width Wp may be wider than the thickness Tp.

  The thickness Tw of the wood block is typically about 5-50 mm, with a more common thickness being about 5-25 mm, or about 7-15 mm, most typically about 10 mm.

  Usually, the thickness Tw of the wood block 10 may be substantially the same as or exactly the same as the thickness Tp of the foamed polymer block 11.

  The width Ww of the wood block 10 is wider than the width Wp of the foamed polymer block 11. As a non-limiting example, the width Wp of the foamed polymer block 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 block 10.

  As described above, the floor panel 1 ″ has a core formed by alternately arranging blocks of wood and foamed polymer along substantially the entire length excluding one or both short sides. Is a reinforced interior formed from wood having a quality higher than that of the wood block 10, a different type of wood from the wood block 10, and at least one of different fiber directions, for example, a direction perpendicular to the fiber direction of the wood block. The inset can also be formed using other materials such as MDF, HDF, polymer or polymer composite (eg, fiber reinforced polymer). Each inset is a floor panel 1 " Less than 15%, preferably less than 10%, less than 5% or less than 3%.

  Such insets may additionally or additionally be provided on one or both of the longitudinal edges. In such a case, the inset extends along all or part of the longitudinal edge and orthogonal to the main direction of the floor panel.

  With reference to FIGS. 3 and 4, the floor panel 1 ″ may be provided with joining systems 30, 31, 32, 33 suitable for interconnection with similar or identical floor panels. Arranged to provide a mechanical or shape-fitting fix, either horizontally or vertically, or both, i.e., multiple floor panels can be wholly or partially integrated without the use of adhesives And fixed.

  In one embodiment, the long side joining systems 30, 31 may be the same as the short side joining systems 32, 33. In another embodiment, the long side bonding systems 30, 31 may differ from the short side bonding systems 32, 33 with respect to, for example, at least one of the shape and mechanical properties of the bonding system.

Different systems for mechanical interconnection of floorboards are known and their manufacturing methods are also known. Non-limiting examples of such systems are WO94 / 26999A1 US 4,426,820, DE121175, DE19851200C1, FR26775174, WO99 / 66151, WO97 / 47834, JP3169967, WO96 / 27721, GB1430423, WO02 / 55809, US4,819. 932, EP 1863984A1 and EP1802827A1, the entire contents of which are hereby incorporated by reference.
Accordingly, further description of the locking system may not be necessary.

  With reference to Figs. 6a-6c, a method for manufacturing a floor panel 1 "will be disclosed.

  On the first sheet, which is the balance layer 12 or the decorative layer 13, a block 10 of wood that has been cut in advance and a block 11 of foamed polymer that has been formed in advance by cutting or molding, for example, are arranged in the same way. . Before bonding the blocks 10 and 11 to the first sheet 12, an adhesive is provided on at least one of the first sheets 12 and 13 and the side surfaces of the blocks 10 and 11 facing the first sheet. Also good. Further, the second sheet 13 is prepared, and an adhesive is provided on at least one of the side surface facing the blocks 10 and 11 and the side surface of the blocks 10 and 11 facing the second sheet. And then the second sheet 13 is joined to those blocks.

  The blocks 10 and 11 are arranged along the longitudinal direction I so as to be adjacent to each other. In the longitudinal direction L of the floor panel, a small gap may be provided between the paired members of each adjacent block. The gap is about 0.1-5 mm, preferably about 1-3 mm.

  After the sheets 12, 13 and the blocks 10, 11 are joined, a batch or continuous pressure is applied, for example, by a roller or a belt press. The pressure may be supplemented by heat or other means of activating the adhesive, such as ultrasound, microwave, etc.

  These steps are typically performed to provide a blank having a size on the order of, for example, about 1.2 m × 2.4 m. Next, this blank is cut into a plurality of floor panel blanks 1 '. That is, the blank has the general shape of the final floor panel 1 "but does not have the joining systems 30, 31, 32, 33 formed along its edges. Next, the floor panel blank 1 ' May be milled and optionally added with individual elements for providing the locking systems 30, 31, 32, 33, for example fixing joints, fixing elements, fixing stripes, etc.

  The decorative layer 13 may be formed of a solid woody sheet, and typically has a thickness of about 2-5 mm, and often about 3 mm. The wood sheet may be composed of a single or several wood blocks, or a plurality of thin plates for forming a block pattern on the surface. Usually most or at least some of these sheets are narrow and extend substantially parallel to the longitudinal direction L of the floor panel. Further, as seen in the case of a floor panel constituting a so-called Dutch floor pattern, some thin plates extend perpendicular to the longitudinal direction L of the floor panel.

  As another example, the decorative layer may be formed of a plurality of layers such as a thin surface layer and a reinforcing layer bonded together by lamination or adhesion. The surface layer may be formed, for example, from a thin wood veneer or laminate of 0.5-2 mm, i.e. an artificially patterned layer (e.g. a print), and a filler that hardens the surface and It can be laminated or integrated with a wear layer comprising a polymeric material containing additives. The reinforcing layer may be formed using plywood, MDF, HDF or other sheet material.

  The decorative layer 13 may be natural wood or wood veneer. That is, it may be uncoated or any surface finish such as, for example, a lacquer, wax, oil, varnish coat or treatment, or a surface treatment based on acrylic or urethane.

  The balance layer 12 may be formed of a thin sheet of 0.5-2 mm wood or plywood. The balance layer may also be formed using a polymer film, a woven or non-woven sheet, for example, a pulp-based material such as paper, or other wood and polymer composites.

  Typically, a floor panel is a part of a set of floor panels that are substantially identical, which provides an integrated flooring.

  Hereinafter, a blank forming method according to a first modification will be described with reference to FIGS. 7 (a) to 7 (d). A first structural layer such as the balancing layer 12 (or the decorative layer 13) is provided (FIG. 7a). Several wood blocks 10 are arranged on the first structural layer. It is also optional to stick the wood block 10 to the structural layer (temporarily or permanently). The wood blocks 10 are arranged at intervals along the main direction L of the blank.

  An easily expandable polymer resin 9 is placed in the space between the wood blocks (FIG. 7b). The polymer resin may include, for example, one or more foaming agents.

  For example, a second structural layer such as the decorative layer 13 (or the balance layer 12) is disposed, and the wood block 10 is sandwiched between the first structural layer and the second structural layer (FIG. 7c). The second structural layer may be affixed (temporarily or permanently) to the wood block.

  Next, the foaming agent contained in the polymer resin 9 is activated and expanded so as to substantially fill the space between the wood blocks 10. The polymer resin is solidified or cured and cooled, and the foamed polymer block material 11 is provided.

  Activation of the foaming agent can be obtained by applying heat, microwaves, ultrasonic waves, vacuum, ultraviolet light, and the like.

  Activation of the foaming agent will also activate the adhesive or other attachment means for attaching the structural layer to the wood block.

  As a modification of this method, the wood block 10 may be sandwiched between the structural layers 12 and 13 before the resin 9 is introduced. In this case, the resin is continuously injected into the space formed between the wooden block and the structural layer. In such a case, the resin is activated immediately after being introduced, for example, by touching the outside air, although it is not always necessary.

  A non-foamable and fillable polymer resin can be injected into the space formed between the wood blocks or between the other block materials.

  In addition to providing the foamed polymer block material 11, the resin 9 may adhere both the block layer, the foamed polymer block material, and the wood block to the structural layer. For example, the wooden block may be designed or arranged so that a sufficient amount of resin enters between the wooden block and the structural layer, and bonded.

  With reference to Fig.8 (a) and FIG.8 (b), the manufacturing method of the blank which concerns on another modification is demonstrated.

  The foamed polymer block material 11 has a thickness Tp that exceeds the thickness Tw of the wood block 10 (FIG. 8a). The block may be provided as a preformed block or by activating a foaming agent prior to disposing the second structural layer.

  Next, the 2nd structure layer 13 is affixed and the foaming polymer block material 11 is compressed (FIG. 8b). The pressure is applied in the pressing step described with reference to FIGS. 6 (a) to 6 (c).

  With reference to FIG. 9A to FIG. 9C, a method for manufacturing a core (without a structural layer) will be described.

  In the first embodiment (FIG. 9 (a)), the core is made of, for example, a wood block 10 and a foamed polymer via adhesion (surface to surface) to form a continuous core without any structural layer. It can be provided by alternately connecting the block members 11.

  If the foamed polymer block material 11 is relatively flexible, the core can be bent and wound on a roll.

  In the second embodiment (FIG. 9B), the core can have a web 20 on its main surface to which the blocks 10, 11 are affixed in a manner similar to that disclosed for the first structural layer 12.

  The web 20 may be a polymer film, a nonwoven web, a woven web, a paper-based or pulp-based web such as paper, a rubber film, or the like. The web is then sufficiently flexible and can be bent and wound on a roll. The web has a thickness in the range of about 0.1-3 mm, preferably about 0.1-1 mm.

  In the third embodiment (FIG. 9C), the second web 21 can be provided on the second surface Sc1 of the core. The second web may be the same as the first web or may be a different type of material.

  For example, upon activation, it is possible to form a web of material that acts as a binder, adhesive, or glue to the core and / or structural layer, or both. For example, upon activation, a coating of a material that acts as a binder, adhesive or glue can be applied to the core or structural layer, or both, or the web can be impregnated with the material. If such materials are sticky or activated by pressure, it is possible to provide a protective film on one or both of the exposed surfaces of the webs 20,21. And such a protective film can be removed when the core which has a web is joined to a structural layer, for example.

  The panel forming method described with reference to FIGS. 6 (a) to 6 (d), FIGS. 7 (a) to 7 (d) and FIGS. 8 (a) to 8 (b) is shown in FIG. 9 (a). It can be seen that it can be applied to the formation of the core described with reference to FIG. 9 (c), cope with the apparent stickiness or viscosity, for example via a protective film, and apply pressure properly.

  And the core which can be wound up on a roll can be provided as typically shown in FIG. The core is then withdrawn from the roll and any structural layer, such as, for example, a decorative layer or backing layer of wood or laminate structure, under pressure Fp to produce a substantially continuous blank. Can be stacked.

  It will be appreciated that the above description of blank manufacture is equally applicable when it is desired to manufacture directly rather than dividing the blank into several pieces to form a panel blank.

  The combination of wood block and foamed polymer block material should be understood as an example of the present disclosure. More generally, the wood block may be the first block material and the foamed polymer block material may be the second block material.

  Thus, the first block material may be provided from other materials, such as polymer / plastic material, rather than wood. The block may be formed, for example, from a composite material that includes at least one of a binder, such as a polymer substrate, one or more fillers, and one or more reinforcing fibers.

  Examples of fillers include one or more of wood chips, wood particles, wood flour (cutting chips, wood flour) or wood fibers, mineral fillers (calcium, dolomite, etc.), polymer fillers (eg recycled polymer) Chunks or particles, rubber or rubber-like material).

  Examples of reinforcing fibers include one or more of glass fibers, carbon fibers, plant fibers (eg, hemp, grass, bamboo or wood fibers or wood yarn) or polymer fibers.

  The first block material can be formed using so-called “artificial wood” or “recycled wood”, which are known, for example, from WO2009 / 140136A2 and WO2010 / 082137A1. The entire contents are included here as references.

  Examples of polymer matrices include one or more of thermoplastic materials (polyethylene, polypropylene, etc.), epoxies, polyurethanes, thermosetting resins (phenol, melamine, urea or combinations thereof), acrylics and polyesters. .

  The second block material may differ from the first block material with respect to at least one of material type, material composition, material density, material hardness, and tensile strength ratio of the material. That is, it may be formed from a completely different material, or may be formed from the same material as the first block material, but at a different density than the first block material (eg, expanded), although the ratio is different. It may be formed or may be processed to obtain a higher altitude or lower hardness. Typically, the first block material has a higher modulus of elasticity than the second block material along direction I, which is perpendicular to or otherwise intersects with the main direction L of the core. Such a block becomes harder. This is obtained, for example, by placing elongated fibers extending substantially perpendicular to the main direction L of the core.

  The second block material may be substantially less dense than the first block material due to, for example, expansion.

  In another example, the second block material may be substantially denser than the second block material, for example, because it includes a relatively heavy filler. This would be desirable to attenuate the sound.

  The first block material can be selected to satisfy bending strength and joint strength, and the second block material can provide other characteristics such as weight reduction, cost reduction, and / or sound reduction. May be selected.

  The second block material described above is formed using any material having at least one of low cost, low density, and low tensile strength in a direction along the main direction of the wood fiber of the wood block. it can.

  The second block material can include an artificial wood product.

  A first example of such a material is a so-called LDF (low density fiber board) or VLDF (very low) formed by molding or compression molding at least one of wood chips, wood particles and wood powder. Density fiber board). Such materials can be molded in a wet or humid state and do not require additional binders or trace amounts of binder are added.

  For example, an LDF board having a density of 160-500 kg / m 3 can be used.

  In another example, a VLDF board having a density of 200-300 kg / m 3 can be used. 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 entirety is hereby incorporated by reference.

  In yet another example, an ULDF (ultra-low density fiber) board having a density of 50-200 kg / m 3 may be used. Such a fiberboard is known by Xie, Y. et al., "Manufacture and Properties of Ultra-Low Density foamed Fiberboard from Wood Fiber", BioResources 6 (4), 4055-4066 (2011), The entire contents are included here as references.

  The low-density, ultra-low density, or ultra-low density fiber board is substantially free of a binder (compression molding under wet / humidity), contains a binder, or is added with an additive. Can have.

  Foamed polymer block material or second block material, polymer base material, wood chip, wood particle, wood powder (cutting waste, wood powder) or wood fiber, mineral filler (calcium, dolomite, etc.), polymer Can be replaced with non-foamed synthetic polymer block materials that contain fillers (eg, recycled polymers, rubber or rubber-like materials), or supplemented with these non-foamed synthetic polymer block materials It is.

  For example, to improve properties such as strength, friction (reduction) or wear, a surface treatment is applied to the exposed portion of the second block material of wood fiber (eg, LDF, VLDF, ULDF) or filled polymer material. You may give it. Such treatment can include, for example, the penetration of substances such as lacquers and thermosetting polymers, or the application of coatings.

  At least one type of block material has an angle between normals of major faces of adjacent block material pairs of the same type (with at least one other block material in the middle), preferably 10 °, 15 ° It may have sufficient flexibility to allow the core to bend over 25 ° or 25 °.

  Bending is also possible and may be facilitated by the longitudinal gap between the first block material and the second block material that are juxtaposed most recently. Such a gap may be about 0.1-5 mm, preferably about 0.5-3 mm, more preferably 1-3 mm.

  Also, where relevant, the webs 20, 21 may be sufficiently flexible to allow such bending, as described above.

  It is understood that the core can include two or more types of block materials that are alternately disposed in their main direction L, each main direction I being substantially orthogonal to the main direction L.

  The above blank, panel blank and floor panel are disclosed as a three-layer structure (decorative layer, core layer and balance layer), but the core of the present disclosure includes a two-layer panel, that is, a decorative layer and a core layer. It is also understood that a panel including can be used. Such panels will be installed and attached to the subfloor. They may have the flexibility to expand to absorb or match subfloor height changes.

In a specific embodiment, the following core types can be mentioned:
A combination of a wood block (first material) and a filled foam polymer block material or an unfilled foam polymer block material (second material);
A combination of a wood block (first material) and a low density fiberboard (ULDF, VLDF, LDF) block (second material);
A combination of a wood block (first material) and a filled non-foamed polymer block material (second material).
Such a core can be used in floor panels having any type of decorative and balance layers disclosed herein.

Claims (15)

A decorative layer (13);
A core layer (10, 11) disposed under said decorative layer (13) when the floor panel is oriented substantially horizontally;
The balance layer,
With
The core layer is sandwiched between the balance layer and the decorative layer,
The core layer is a plurality of wood blocks (10), each main fiber direction being substantially parallel to a surface (So) defined by the main surface of the floor panel, A plurality of wood blocks (10) arranged to be substantially orthogonal to the direction (L),
The core layer (10, 11) includes a plurality of second block members (11) made of a material different from the plurality of wood blocks (10),
Along the main direction (L) of the floor panel, the core layer includes alternating portions formed by the wood block (10) and the second block material (11),
The second block material has a lower density than the wood block, or has a lower tensile strength in a direction parallel to the main fiber direction than the wood block, or both.
The wood block (10) includes a wood block made of wood material,
The material of the wood is
1960 Swedish "Grona boken" (The Green book) standard V or less, preferably VI or VII or less,
Less than B, preferably less than C or less than D in the 1994 Swedish “Blaa boken” (The Blue book) standard, and less than G4-2 / G2 / 2 of the 2000 European EN1611-1 standard, preferably G4 -3 / G2-3 or less or G4-4 / G2-4 or less,
A floor panel that fits at least one of the following. The floor panel according to claim 1, wherein a width of the second block material (11) is shorter than a width of the wood block (10) along a main direction (L) of the floor panel. Along the main direction (L) of the floor panel, the width of the expanded second block material (11) exceeds 5% of the total length of the floor panel, preferably 10%, 20%, 30% or The floor panel according to claim 1, which exceeds 40%.   2. The floor panel according to claim 1, wherein the second block material includes a foamed polymer block material that is at least one of expanded polyethylene, expanded polypropylene, and expanded polystyrene obtained by extruding polystyrene foam.   The floor panel according to claim 1, wherein the second block material includes an artificial wood product.   The floor panel according to claim 1, wherein the second block material includes a non-foamed polymer material including a filler.   The floor panel according to claim 1, wherein the core layer further includes a reinforcing inset portion.   The floor panel according to claim 1, wherein the second block member (11) has a coating on a surface of an end portion where the second block member is exposed. The floor panel according to claim 1, wherein the second block member (11) has a portion having a high density at an end portion where the second block member is exposed.   The floor panel according to claim 1, wherein the decorative layer (13) includes wood. In order to form a core layer, a plurality of elongated wooden blocks (10) are juxtaposed on the same plane so that their longitudinal directions (I) are parallel to each other,
Providing the core layer with at least one decorative layer (13) for forming a panel blank;
Providing a balance layer to the core layer, wherein the core layer is sandwiched between the balance layer and the decorative layer;
Cutting the panel blank such that the longitudinal direction (l) of the wood block is substantially perpendicular to the main direction (L) of the floor panel blank to form an elongated floor panel blank;
Along the main direction (L) of the floor panel blank, the wood block (10) and the plurality of second block members (11) are alternately arranged,
The second block material having at least one of a lower density than the wood block and a tensile strength in a direction parallel to the main fiber direction is lower than that of the wood block (10);
Said wood block (10) comprising a wood block of wood material;
Including
The material of the wood is
1960 Swedish "Grona boken" (The Green book) standard V or less, preferably VI or VII or less,
Less than B, preferably less than C or less than D in the 1994 Swedish “Blaa boken” (The Blue book) standard, and less than G4-2 / G2 / 2, preferably G4-3 of the 2000 European EN1611-1 standard / G2-3 or less or G4-4 / G2-4 or less,
A method of manufacturing a floor panel having at least one of the following.   The manufacturing method according to claim 11, further comprising forming locking means (30, 31) along the main direction (L) of the floor panel blank.   The manufacturing method according to claim 12, further comprising subjecting at least a part of the mechanical joining means to a surface treatment.   The manufacturing method according to claim 13, wherein the surface treatment includes applying a coating to an exposed portion of the second block material. The manufacturing method according to claim 13 or 14, wherein the surface treatment includes thermoforming an exposed portion of the second block material.

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