WO2005072957A1 - Panneau composite encapsule renforce et procede de fabrication dudit panneau - Google Patents

Panneau composite encapsule renforce et procede de fabrication dudit panneau Download PDF

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Publication number
WO2005072957A1
WO2005072957A1 PCT/IN2004/000021 IN2004000021W WO2005072957A1 WO 2005072957 A1 WO2005072957 A1 WO 2005072957A1 IN 2004000021 W IN2004000021 W IN 2004000021W WO 2005072957 A1 WO2005072957 A1 WO 2005072957A1
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WO
WIPO (PCT)
Prior art keywords
reinforced
layer
composite panel
foundation layer
encapsulated composite
Prior art date
Application number
PCT/IN2004/000021
Other languages
English (en)
Inventor
Tripunitara Veeraraghavan Sreeram
Original Assignee
Sreeram Tripunitara Veeraragha
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Filing date
Publication date
Application filed by Sreeram Tripunitara Veeraragha filed Critical Sreeram Tripunitara Veeraragha
Priority to PCT/IN2004/000021 priority Critical patent/WO2005072957A1/fr
Publication of WO2005072957A1 publication Critical patent/WO2005072957A1/fr

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/18—Layered products comprising a layer of synthetic resin characterised by the use of special additives
    • B32B27/20—Layered products comprising a layer of synthetic resin characterised by the use of special additives using fillers, pigments, thixotroping agents
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
    • B32B17/02—Layered products essentially comprising sheet glass, or glass, slag, or like fibres in the form of fibres or filaments
    • B32B17/04—Layered products essentially comprising sheet glass, or glass, slag, or like fibres in the form of fibres or filaments bonded with or embedded in a plastic substance
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B21/00—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board
    • B32B21/10—Next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/36—Layered products comprising a layer of synthetic resin comprising polyesters
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F13/00—Coverings or linings, e.g. for walls or ceilings
    • E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
    • E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/40—Properties of the layers or laminate having particular optical properties
    • B32B2307/412—Transparent
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/54—Yield strength; Tensile strength
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/554—Wear resistance
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/584—Scratch resistance
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2309/00—Parameters for the laminating or treatment process; Apparatus details
    • B32B2309/02—Temperature
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2309/00—Parameters for the laminating or treatment process; Apparatus details
    • B32B2309/04—Time
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2309/00—Parameters for the laminating or treatment process; Apparatus details
    • B32B2309/12—Pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2315/00—Other materials containing non-metallic inorganic compounds not provided for in groups B32B2311/00 - B32B2313/04
    • B32B2315/06—Concrete
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2317/00—Animal or vegetable based
    • B32B2317/16—Wood, e.g. woodboard, fibreboard, woodchips
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2471/00—Floor coverings
    • 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

Definitions

  • Wood Science & Technology and further belongs to woodworking industry.
  • thermoplastic foundation layers for flooring and panels with higher thickness is limited due to the high cost of the resins.
  • Lower thickness on the other hand lends itself to less dimensional stability of the flooring tiles or panels due to the reduced value of section modulus.
  • Stone, cement and ceramic substrates are dimensionally stable as also moisture / vapour resistant. They are however available only in certain finishes due to processing limitations. Ceramic and stone substrates also have to be installed with 2-4 mm joints of filler material. Unlike wooden panels, commercially available ceramic and stone materials are not dimensionally precise due to the high costs to be incurred in calibrating and machining them.
  • U.S Pat No. 5,976,689 discloses a Coated Synthetic Resin Board tile.
  • This flooring uses a synthetic resin as a thin foundation foundation layer with a wood veneer decorative surface.
  • U.S. Pat No. 5,437,934 they disclose a Coated Cement Board Tile. While the cement board tile disclosed suffers from the serious setback that thickness calibration and edge processing is difficult and expensive, the former tile uses a high content of expensive synthetic resin and is particularly not suited for thicker panels due to economic and environmental reasons.
  • U.S Pat No. 3,231,457 includes wood flooring in which a backing made from waste rubber is used as a foundation layer with a wood veneer surface.
  • Elmendorf, U.S Pat No. 3,287,203 describes a plywood subfloor onto which is placed a tile having a wood fiber hardboard foundation, a natural wood layer and a vinyl resin coating.
  • U.S Pat Application PubKcation No. US2003 / 0024637 discloses an abrasion resistant laminate formed on a polymeric substrate.
  • none of the known floor tile or panel methods provide the unique combination of using thermally stable materials such as ceramic, cement tiles and stone with heat insulating materials like wood in the same panel with a water resistant encapsulation interface which can be sanded, calibrated and machined cost-effectively.
  • FIG. la & lb are general process flow diagrams illustrating the process of the present invention.
  • FIG.2 shows the build up of the layered structure of the reinforced cellulose based foundation layer.
  • FIG.3 shows the cross section of a reinforced sand polymer concrete foundation layer.
  • FIG.4 shows a variation of the embodiment represented in FIG.3.
  • FIG.5 shows the cross section of a reinforced cement tile foundation layer.
  • FIG.6 shows the cross section of a reinforced and encapsulated foundation layer.
  • FIG.7 shows the cross section of a reinforced encapsulated foundation layer with a decorative layer adhered to it.
  • FIG.8 shows the cross section of a reinforced and encapsulated cellulose based panel foundation layer.
  • FIG.9 shows the cross section of a reinforced and encapsulated cellulose based panel foundation layer with a decorative layer adhered to it.
  • FIG.10 shows the cross section of a reinforced and encapsulated cellulose based panel foundation layer with a stratified decorative layer adhered to it.
  • FIG.11 illustrates the cross section of a reinforced encapsulated composite panel with profiled edges.
  • FIG.12 illustrates the cross section of a reinforced encapsulated composite panel with profiled edges and an encapsulated decorative layer.
  • FIG.13 illustrates the cross section of a cellulose based reinforced encapsulated composite panel with profiled edges.
  • FIG.14 illustrates the cross section of a reinforced encapsulated cellulose based composite panel with a stratified decorative layer and tongue and groove edges.
  • FIG.15 illustrates the cross section of a reinforced encapsulated composite panel with tapered profile edges and a stratified decorative layer.
  • FIG.16 shows the bottom view of a preferred embodiment of this invention in which a plurality of tiles are stacked and encapsulated together to form a foundation layer.
  • FIG.17 shows the top view of a reinforced encapsulated composite panel with a decorative layer consisting of wood, metal, leather and inlay.
  • the present invention comprises reinforced encapsulated composite panel and method for making the same.
  • Reinforced encapsulated composite panel is durable, stable and vapour resistant panel ideally suited for wall cladding and floor covering applications.
  • the preferred embodiments in the invention described herein are not intended to limit the scope of this invention, as it is well known to those skilled in the art.
  • FIG. la & FIG. IB illustrate the general process for manufacture of the preferred embodiment of this invention.
  • the reinforced encapsulated composite panel consist of 5 layers in three-dimensional space.
  • the stratum which provides structural support and integrity to the product, is the foundation layer.
  • the foundation layer is selected from the group consisting of sand polymer concrete tiles, natural stone tiles, ceramic tiles, cement tiles and reinforced cellulose based panel.
  • the second layer is the encapsulation layer, which not only acts as an interface between the foundation layer and the decorative layer, but also reinforces the foundation layer.
  • the decorative layer which comes, next renders the aesthetic appeal to the product.
  • the protective layer safeguards the decorative layer and the wear layer is that which comes in contact with the end user of the panel and gets abraded during use.
  • cellulose based panel is alternated with glass fiber mats and resin mixture to form a reinforced cellulose based foundation layer.
  • Cellulose based panels such as plywood; fiberboard, hardboard and LVL are available in large sizes such as 2400 x 1200 mm. They are however not very stable and hence have to be reinforced in order to build rigidity and stability into the foundation layer.
  • the distinct advantage with using such foundation layers is that it permits the manufacture of large size reinforced encapsulated composite panels which could find use as wide plank flooring panels and wall panels. While dimensionally stable reinforced encapsulated composite panels up to 2400 x 1200 mm can be produced in thick nesses as low as 7 mm, the preferred thickness for panels larger than 2400 x 600 mm is 9 -25 mm.
  • cellulose based panels 1 selected from hardboard, fiber board, plywood and Laminated Veneer Lumber (LVL) are pressed with alternating layers of resin mixture 2 and glass fiber mats 3 to form a reinforced cellulose based foundation layer 11.
  • LDL Laminated Veneer Lumber
  • Using a higher density cellulose based panel ensures higher Brinell hardness in the finished product.
  • Water resistant V313 hardboard or high-density fiberboards with density exceeding 1100 kg/m3 are such high- density panels.
  • These sheets come in sizes of 8 ft x 4 ft or 2440 mm x 1220 mm.
  • Cellulose based panels of thickness 2 to 25 mm can be used although 3mm to 5 mm thick panels are preferred.
  • Sheets of the selected cellulose based panels are sanded preferably with Grit 60 Aluminium Oxide sandpaper in a wide belt sander.
  • a resin mixture is prepared from about 20% to 60% by weight of unsaturated polyester resin, 39% to 80% by weight of filler and 1% to 2% by weight of methyl ethyl ketone peroxide catalyst.
  • the preferred unsaturated polyester resins are Mechster sold by Mechemco Industries or Norpol sold by Reichhold Chemicals Inc or similar.
  • the preferred unsaturated polyester resins should have a Tensile Strength (filled) of more than 30 MPa, Flexural Strength (filled) of more than 55 MPa, Barcol Hardness (filled) of more than 50 and a Heat Deflection Temperature of more than 85 C. Any other thermo set or thermoplastic resin can be used as long as it cures to a solid that can be worked on and is moisture resistant.
  • Other additives such as dispersing agents, air release agents and inhibitors are added in a conventional manner.
  • Glass fiber mats are cut in the same size as the cellulose based panels. Glass fiber mats of weights ranging from 150 gm/m2 to 600 gm/m2 can be used, although 225 gm/m2 mats are preferred. These mats are thin enough to allow the resin mixture to flow through the mats thereby bonding the mats firmly to the cellulosic panels, while being strong enough to reinforce the panels.
  • the number of layers of the cellulosic panels in the composite can range from 2 to 12.
  • the number of layers of the glass fiber mat can range from 1 to 11. The number of layers depends on the thickness of the final product and the thickness of the cellulose based panel chosen. In this preferred embodiment at least 2 layers of cellulose-based panel and 1 layer of glass fiber mat are used.
  • the resin mixture 2 is spread on the cellulose-based panel 1 using a rubber or steel roller, which is preferably mechanised.
  • the spread rate of the resin mixture is maintained between 200 ml to 400 ml per sq.m. of coated area.
  • a glass fiber mat 3 As shown in FIG.2, between two cellulose-based panels coated with the resin mixture is placed a glass fiber mat 3. This arrangement is followed for as many layers of cellulose based panels as required.
  • the materials as described above are stacked and loaded into a pressing device.
  • This device can be a platen hydraulic press with single or multiple daylights or a simple pneumatic or clamp press. While the applied pressure can vary from 0.5 kg/cm2 to 5 kg/cm2, a pressure range of 1.5 kg/cm2 to 2.0 kg/cm2 is preferred.
  • a platen hydraulic press with a large daylight gap of 500 mm or more so that better economies of scale can be achieved.
  • the resin mixture reaches a peak exotherm after about 15 to 25 minutes.
  • the assemblies of reinforced cellulose based foundation layers 11 get fully cured in 8 - 12 hours at a room temperature of 25 C. While shorter cure times are feasible, it is preferred that the cold cure time be at least 5 hours in order to achieve the best stability possible. While in the preferred embodiment, a high temperature curing process is feasible; a cold cure process is preferred to maintain n ⁇ iimal movement of the panels.
  • sand polymer concrete tiles are used as foundation layer 10.
  • Sand polymer concrete tiles can be cast in thick nesses as low as 5 mm.
  • the thickness of the tile has to be increased while casting large format tiles. For example, for al200 x 600 mm tile, the thickness would have to be at least 6 mm in order to maintain enough rigidity and breaking strength.
  • a homogeneous mixture of sand, unsaturated polyester resin, Methyl Ethyl Ketone Peroxide (MEKP) catalyst, air release additives and inhibitors are mixed to form a polymer mortar 4 which is cast in moulds with glass fiber mat reinforcement 3 as shown in FIG.3 and FIG.4 at low pressures of 0.5 kg/m2 to 0.75 kg/m2.
  • the polymer concrete mortar 4 contains 85% to 90% of sand, 9% to 14% of unsaturated polyester resin and about 1% to 2% of MEKP catalyst. Glass fiber mat reinforcement is provided either on both top and bottom as shown in FIG.3 or only in the middle of the polymer concrete mortar as shown in FIG.4.
  • Preferred unsaturated polyester resins are similar to those used in the solid surface casting industry such as Mechster sold by Mechemco Industries or Norpol sold by Reichhold Chemicals Inc or similar.
  • the preferred unsaturated polyester resins should have a Tensile Strength (filled) of more than 30 MPa, Flexural Strength (filled) of more than 55 MPa, Barcol Hardness (filled) of more than 50 and a Heat Deflection Temperature of more than 85 C.
  • the application of pressure is to ensure compaction of the polymer concrete mortar. Additionally, the mold can be vibrated in order to achieve better compaction. The pressure is applied only for 1-2 minutes in order to achieve compaction and the mould is set-aside for 12-24 hours for a full cure. While in the preferred embodiment, a high temperature curing process is feasible; a cold cure process is preferred to maintain better stability of the tiles.
  • the cured product is a sand polymer concrete tile, which is ready to be used as a foundation layer 10.
  • cement tiles are used as the foundation layer 10 as shown in FIG.5.
  • Cement tiles have to be cast in thick nesses of 5 mm to 25 mm in order for them to be strong. Properly cast cement tiles with appropriate protection can last many years and are very durable.
  • the mortar has 20% to 80% by weight of filler or sand and 10% to 50% by weight of white cement or Portland cement along with required quantities of water. Vibration and pressure of 1kg /cm2 to 3 kg/cm2 is applied on the mortar.
  • Tile making presses or dies can be used for this purpose industrially.
  • These tiles are allowed to cure for 5-7 days with frequent watering to allow full cure. After cure, the tiles are allowed to stabilize for 4-5 days in a dry area. After stabilization, the tiles are ground to an accuracy of 1 mm on their thickness in a tile-grinding machine where grinding stones are mounted on a rotating spindle. The tiles are kept stationary while the abrasive stones grind away the excess concrete and provide a cement tile with thickness accuracy of 1 mm. The cement tiles are now ready to be used as a foundation layer 10. An accuracy of 0.1 mm is required in order to glue a decorative surface on top of this concrete tile. The rough grinding to an accuracy of 1 mm helps reduce the thickness of the encapsulation layer required on the top of the cement tile foundation layer.
  • ceramic tiles are used as the foundation layer 10 as shown in FIG.6 and FIG.7.
  • Ceramic tiles are manufactured commercially by 1200 x 600 mm tile, the thickness would have to be at least 6 mm in order to maintain enough rigidity and breaking strength.
  • a homogeneous mixture of sand, unsaturated polyester resin, Methyl Ethyl Ketone Peroxide (MEKP) catalyst, air release additives and inhibitors are mixed to form a polymer mortar 4 which is cast in moulds with glass fiber mat reinforcement 3 as shown in FIG.3 and FIG.4 at low pressures of 0.5 kg/m2 to 0.75 kg/m2.
  • the polymer concrete mortar 4 contains 85% to 90% of sand, 9% to 14% of unsaturated polyester resin and about 1% to 2% of MEKP catalyst. Glass fiber mat reinforcement is provided either on both top and bottom as shown in FIG.3 or only in the middle of the polymer concrete mortar as shown in FIG.4.
  • Preferred unsaturated polyester resins are similar to those used in the solid surface casting industry such as Mechster sold by Mechemco Industries or Norpol sold by Reichhold Chemicals Inc or similar.
  • the preferred unsaturated polyester resins should have a Tensile Strength (filled) of more than 30 MPa, Flexural Strength (filled) of more than 55 MPa, Barcol Hardness (filled) of more than 50 and a Heat Deflection Temperature of more than 85 C.
  • the application of pressure is to ensure compaction of the polymer concrete mortar. Additionally, the mold can be vibrated in order to achieve better compaction. The pressure is applied only for 1-2 minutes in order to achieve compaction and the mould is set-aside for 12-24 hours for a full cure. While in the preferred embodiment, a high temperature curing process is feasible; a cold cure process is preferred to maintain better stability of the tiles.
  • the cured product is a sand polymer concrete tile, which is ready to be used as a foundation layer 10.
  • cement tiles are used as the foundation layer 10 as shown in FIG.5.
  • Cement tiles have to be cast in thicknesses of 5 mm to 25 mm in order for them to be strong. Properly cast cement tiles with appropriate protection can last many years and are very durable.
  • cement tiles are made by pouring cement mortar 5 into a mold wherein a galvanized iron mesh or fiber mat 6 has been placed.
  • the mortar has 20% to 80% by weight of filler or sand and 10% to 50% by weight of white cement or Portland cement along with required quantities of water. Vibration and pressure of 1kg /cm2 to 3 kg/cm2 is applied on the mortar.
  • Tile making presses or dies can be used for this purpose industrially.
  • These tiles are allowed to cure for 5-7 days with frequent watering to allow full cure. After cure, the tiles are allowed to stabilize for 4-5 days in a dry area. After stabilization, the tiles are ground to an accuracy of 1 mm on their thickness in a tile-grinding machine where grinding stones are mounted on a rotating spindle. The tiles are kept stationary while the abrasive stones grind away the excess concrete and provide a cement tile with thickness accuracy of 1 mm. The cement tiles are now ready to be used as a foundation layer 10. An accuracy of 0.1 mm is required in order to glue a decorative surface on top of this concrete tile. The rough grinding to an accuracy of 1 mm helps reduce the thickness of the encapsulation layer required on the top of the cement tile foundation layer.
  • ceramic tiles are used as the foundation layer 10 as shown in FIG.6 and FIG.7.
  • Ceramic tiles are manufactured commercially by compressing clay and firing the bisques at high temperatures. They are extremely stable and water resistant.
  • small format ceramic tiles can be arranged as an array.
  • an array of small format ceramic tiles are placed together and encapsulated in order to produce a large format reinforced encapsulated foundation layer.
  • a bottom view of this embodiment is illustrated in FIG.16. While unglazed ceramic tiles are preferred, glazed ceramic tiles with rough surface finish on the glazing can also be used as foundation layers.
  • Ceramic tiles commercially available are in lengths and widths ranging from 200 mm to 900 mm with thicknesses in the range of 5-12 mm. Ceramic tiles are very economical, especially the small format tiles.
  • natural stone tiles are used as the foundation layer 10 as shown in FIG.6.
  • Stone tiles are available in wider formats but are much thicker due to the limitations in processing large thin tiles.
  • the thickness of the tile also goes up with the overall size of the tile.
  • 300 x 300 mm tiles would be available in a thickness range of 8-12 mm, commercially available thicknesses of large format stone tiles are 10-20 mm.
  • lower grade stone tiles referred to as 'seconds' are used as foundation layers as long as they are structurally sound.
  • Reinforcement and Encapsulation of the foundation layer is a common step with all the preferred embodiments of this invention.
  • the functions of the encapsulation in the preferred embodiments which use one of ceramic tile, cement tile, sand polymer concrete tile and natural stone foundation layers 10 are: X providing a reinforcement to the foundation layer X providing an interface which can be calibrated so that the resulting reinforced and encapsulated foundation layer has a flat surface and is of even thickness, the cumulative tolerance for both parameters being 0.1mm X providing an interface which can adhere to wood, laminate, leather, inlay and metal X providing a machinable vapour resistant edge, which can be profiled.
  • the reinforced foundation layer itself can be sanded and calibrated and this layer can adhere to wood, leather, inlay and metal.
  • the functions of the encapsulation are: X providing a machinable water and vapour resistant edge which can be profiled X providing a reinforcement to the foundation layer
  • the encapsulation is put on the face and the four edges of the foundation layer.
  • the encapsulation caps the foundation layer 10 as shown in FIG.6 and reinforces it.
  • the encapsulation is put on all the four edges as shown inFIG.8. The encapsulation thus forms a continuous waterproof reinforcing band around the foundation layer with no joints or breaks.
  • the thickness of the encapsulation on the face of the foundation layer is between 0.6 mm and 25 mm although the preferred thickness is 3-6 mm.
  • the preferred thickness of 3-6 mm provides enough reinforcement of the foundation layer while minimizing quantities of the resin. This thickness is also sufficient to compensate for the irregularities in the foundation layer.
  • the width of the encapsulation around the four edges of the foundation layer is between 0.6mm and 100 mm although the preferred width is between 10 mm and 20 mm. This leaves enough material to trim the finished product to get right angle corners as also profile the edges.
  • the decorative layer 8 can also encapsulated on all four edges to seal it against moisture and vapour as illustrated in FIG.12.
  • the decorative layer is encapsulated on all the five exposed sides.
  • this encapsulation of the decorative layer can be of width 0.6 mm to 25 mm although the preferred width is 3-5 mm. A larger width reduces the aesthetic appeal of the product. A large enough width is required in order to seal the edges as also reinforces the decorative layer. Appropriate color pigments are added to the resin mixture to ensure that the color of the encapsulation matches the color of the decorative layer closely or contrasts with it.
  • the encapsulation is carried out as a casting operation in a suitable mold.
  • the mold is made of any conventional mold making material surfaced with a release agent. These materials are used in order to reduce the tooling cost as also take advantage of reusability of the molds.
  • the areas of the mold, which come in direct contact with the resin can be protected with a paper masking tape or a release agent such as carnauba wax.
  • the mold takes the complimentary shape of the encapsulation required.
  • thermosetting resin used is an unsaturated polyester resin.
  • Other thermosetting resins such as modified urethane resins; acrylic resins can also be used.
  • a resin mixture is prepared from about 20% to 60% by weight of unsaturated polyester resin, 39% to 80% by weight of filler and 1% to 2% by weight of methyl ethyl ketone peroxide catalyst.
  • the preferred unsaturated polyester resins are Mechster sold by Mechemco Industries or Norpol sold by Reichhold Chemicals Inc or similar.
  • the preferred unsaturated polyester resins should have a Tensile Strength (filled) of more than 30 MPa, Flexural Strength (filled) of more than 55 MPa, Barcol Hardness (filled) of more than 50 and a Heat Deflection Temperature of more than 85 C. Any other thermo set or thermoplastic resin can be used as long as it cures to a solid than can be worked on and is moisture resistant. Other additives such as dispersing agents, air release agents and inhibitors are added in a conventional manner.
  • the selected foundation layers are placed inside the mold and passed through a stepper motor driven conveyor equipped with an array of photosensitive devices. The photo sensor senses the approach of a mold carrying the foundation layer. The speed of the conveyor is slowed down automatically as the mold arrives under the dispensing nozzles.
  • the dispensing nozzles are fed from a common reservoir equipped with a stirrer.
  • the nozzles are activated by electrically actuated solenoids.
  • the exact quantity of resin mixture is dispensed through each nozzle based on the shape of the mold.
  • the mold then passes and the next mold comes under the nozzle array to receive the resin.
  • the molds containing the encapsulating resin are placed on racks for curing.
  • the racks containing the molds with the encapsulated foundation layers are placed in an oven maintained at 40C in order to speed up the cure of the resin mixture.
  • the mixture gels after about 20-25 minutes and achieves full cure within 5 hours and the molds are ready to be used for the next cycle.
  • the product taken out from the mold is a reinforced and encapsulated foundation layer, which is left to stabilize for 24 hours before calibration and sanding.
  • Encapsulated ceramic tile foundation layers are less brittle and can sustain harder impacts similar to those caused by falling objects. Since the encapsulation layer itself has high impact resistance, it holds the tile together and prevents the ceramic tile from shattering or fragmenting even after heavy impacts. Reinforced Encapsulated ceramic tile foundation layers can withstand an impact of up to 10 kgf/sq.cm.
  • the reinforced encapsulated foundation layers are calibrated in a wide belt sander loaded with a Grit 60 or 80 Aluminum Oxide sandpaper.
  • the wide belt sander should be equipped with a very efficient dust collection system as the resin mixture produces fine dust when sanded.
  • the required accuracy in the calibration is 0.10 mm.
  • the calibrated reinforced and encapsulated foundation layer is now ready to be mated with the decorative layer.
  • the calibrated reinforced foundation layer is coated with a suitable adhesive in order to adhere the decorative layer 8.
  • the decorative layer is chosen from the group consisting of wood, laminate, leather, metal and inlay.
  • the selection of the adhesive depends on the processing infrastructure and the press throughput required. While hot press adhesives such as urea formaldehydes can be used, they are best avoided in order to reduce formaldehyde emissions in the finished product and also because a cold press process leaves more stable product.
  • Isocyanate cross-linked polyvinyl acetate such as Rakollit 80 sold by H.B.Fuller GmbH of Germany is an excellent water resistant adhesive suitable for this application and is preferred in this invention.
  • Bi-component Polyurethane adhesives such as P-28 manufactured by ICA SpA of Italy are also preferred in this invention. These adhesives boast of short press times of 15-20 minutes and are suitable for cold press conditions. Polyester resins with high solids content such as Mechster 1200 manufactured by Mechemco can also be used although the press times are as long as 3-4 hours.
  • Cold pressing is preferred in this invention in order to maximize the stability of the panels. While hot pressing at temperatures of 75C or less is also possible, hot pressing requires the use of balancing layers and also increases the probability of cupping or doming of the finished panels.
  • the chosen adhesive is spread on the foundation layer at a rate of 100 gm to 200 gm per sq.m.
  • the chosen decorative layer is placed on the adhesive layer and the assembly is placed in a press where a uniformly distributed pressure of 1 kg/cm2 to 3 kg/cm2 is applied for 15-25 minutes.
  • the pressed reinforced encapsulated composite panel with the decorative layer as shown in FIG.7, FIG.9 and FIG.10, is allowed to cure for 12 hours and is then ready for final finishing.
  • the end product is a reinforced encapsulated composite panel.
  • the decorative layer is also encapsulated as shown in FIG.12 preferably with an unsaturated polyester resin similar to Norpol 32166- 17 sold by Reichhold Chemicals.
  • the reinforced encapsulated composite panel is coated with an abrasion resistant protective coating 9 or oil based protective coating.
  • UV cured acrylic base coats such as those sold by ICA SpA with ceramers suspended in the resin are preferred in this invention as an abrasion resistant coating.
  • On top of the protective layer 9 is the wear layer.
  • the wear layer is preferably a ceramer suspended UV cured topcoat such as those sold by ICA SpA.
  • the decorative layer can also be coated with an Oil based coating similar to those conventionally used in the industry for wood finishing.
  • the finished reinforced encapsulated composite panel is trimmed along its width and length and profiles machined on the edges.
  • an interlocking profile as illustrated in FIG.ll, FIG.12 and FIG.13 is preferred so that the finished panels may be installed as a floating installation.
  • the edges are only profiled with a taper as illustrated in FIG.15 so that during installation the top ends of the panel meet.
  • a conventional tongue and groove profile as illustrated in FIG.14 is used. Tungsten carbide or diamond tooling is preferred for machining the edges in this invention as they offer better consistency during long production runs.
  • FIG.17 illustrates the top view of a preferred embodiment of the invention in which the decorative layer consists of wood 15, leather 16, metal 17 and inlay 18.
  • a feature of the present invention is to provide dimensionally stable water and vapour resistant reinforced encapsulated composite panels, which are not susceptible to damage by moisture.
  • Another feature of this invention is to provide a panel that is economically feasible and easy to install.
  • Another feature of this invention is that it uses one of stone, ceramic, cement, sand polymer concrete or cellulose foundation layers with a decorative surface chosen from or a combination of wood, and leather while permitting easy calibration, edge profiling and facilitating a panel interlocking system.
  • Another feature of this invention is that it provides panels with waterproof edges, which are dimensionally precise, and those, which can be installed with minimal gaps between panels so as to maximize visual appeal.
  • Yet another feature of this invention is that it provides panels with a lock profile on the waterproof edges such that they can be locked closely with one another and .also be laid as floating installations i.e. without adhering them to the sub-floor.
  • Another feature of this invention is to provide innovative ceramic tile panels that bear structural similarity to glazed ceramic tiles so that they can be installed simultaneously so as to create novel wall and flooring designs.
  • a feature of this invention is to permit a wide range of installation methods i.e. floating installation, tile glue method, cement mortar method or combinations of these methods on a wide range of surfaces including those with existing floors.
  • Yet another feature of this invention is that moisture resistant wooden flooring panels, which can be installed alongside stone and ceramic tiles using the same installation method, can be produced.
  • Another feature of this invention is that since the panels can be installed with minimal gaps between them, it permits use in areas like kitchens where hygiene is of prime importance.
  • Yet another feature of this invention is that wood and wooden veneer panels, which can be used in moisture-laden areas like bathrooms can be produced.
  • a very important feature of this invention is that it enables the combination of moisture resistant thermally stable materials like ceramic with insulating materials like wood. This combination demonstrates exceptional performance in applications where under floor heating is installed.
  • the thermally stable encapsulated ceramic foundation layer protects the upper wooden decorative and insulating layer from large thermal gradients rendering stability and minimal movement to the flooring installation.
  • the reinforced encapsulated composite panels essentially consist of 5 layers in three- dimensional space.
  • the foundation layer is that which provides structural strength and integrity to the product.
  • the encapsulation layer acts as a protection, reinforcement and as an interface between the foundation layer and the decorative layer while facilitating precise rnachining and calibration of the foundation layer.
  • the encapsulation could be in 1 to 6 planes depending on the foundation layer, the decorative layer chosen and the application of the panel.
  • On top of the foundation layer and encapsulation layer is the decorative layer. This layer is that which provides the visual appeal to the product.
  • the protective layer On top of this decorative layer is the protective layer, which safeguards the decorative layer.
  • On top of this protective layer is the wear layer which comes directly in contact with the end user of the panel and which gets abraded.
  • the foundation layer is made of one or more ceramic tiles.
  • the tiles are encapsulated with a resinous mixture consisting of unsaturated polyester resin, catalyst and filler material on all four sides and the face.
  • the encapsulation caps the ceramic tiles and also reinforces the foundation layer.
  • the ceramic tile thus becomes less fragile and can sustain harder impacts.
  • the encapsulated tile is then calibrated to an accuracy of 0.10 mm.
  • Wood, laminate, leather, inlay or metal decorative surface layers are glued on top of the encapsulation layer using appropriate adhesive chosen from polyurethane, polyester or isocyanate cross linked poly vinyl acetate.
  • the decorative layer can also be encapsulated on the four sides to render it wate ⁇ roof.
  • the decorative layer can also be glue-cast on top of the encapsulation layer while the encapsulation itself is formed. In this case the decorative layer is also encapsulated around its four sides rendering it wate ⁇ roof.
  • the panel is then calibrated so that the finished tile is of the required thickness.
  • the foundation layer is a cement tile.
  • Cement tiles are made by pouring filler and water with white cement or Portland cement into a mold in which galvanized iron mesh or fiber reinforcement has been placed! These tiles are allowed to cure for 5-7 days with frequent watering to allow full cure. After curing, the tiles are allowed to stabilize for 4-5 days in a dry area. After the tiles have stabilized, they are encapsulated on the sides and face as described earlier in the case of panels described in the first embodiment. Further processing is also similar to the panels described in the first embodiment.
  • the foundation layer is a sand polymer concrete tile. Sand polymer concrete tiles are cast on molds by mixing sand, unsaturated polyester resin, catalyst and filler material with glass fibre mat used as reinforcement. The tiles are allowed to cure overnight and encapsulated on the sides and face. Further processing is similar to that described for the panels in the first embodiment.
  • a porous stone is chosen from natural stones such as sandstone, limestone or slate.
  • One or more stone tiles are encapsulated with a resinous mixture consisting of unsaturated polyester resin, catalyst and filler material on all the four sides and the top. Since stone tiles available commercially have larger dimensional tolerances, it is necessary to use a thicker encapsulation layer so that there is enough material for calibration to the required thickness. Further processing is similar to the panels described in the first embodiment. It is possible to use waste and off-cuts from natural stone processing for production of these panels. Stone tiles, which are labeled as 'seconds' due to natural defects can also be used.
  • a reinforced cellulose based foundation layer is used.
  • Cellulose based panel materials are those, which have been made with wood or wood based materials. Examples of cellulose based panel materials are fiberboards, plywood, laminated veneer lumber, chipboard, particleboard, hardboard, blockboard, oriented strand board etc. Cellulose based panel materials with high densities are preferred in this invention.
  • a cellulose based panel material is chosen from the group consisting of hardboard, fiberboard, Laminated Veneer Lumber and plywood. Multiple layers of these panels are placed in alternate layers with glass fiber and resin mixture and subjected to l-5kg/cm2 pressure in a pressing device.
  • the resin mixture consists of unsaturated polyester resin, catalyst and filler.
  • the reinforced cellulose based foundation layer is then encapsulated on four sides and calibrated accurately to the required thickness.
  • the decorative layer is then glued on the panel. Since the modulus of rigidity of this reinforced cellulose based panel is not as high as that of ceramic or stone, it is necessary to glue a balancing layer to the bottom so as to prevent cupping or doming of the panel.
  • the reinforced encapsulated composite panels described above shall find extensive application as wall cladding and floor covering.
  • a decorative layer chosen from or a combination of wood and leather, coated with a UV resistant protective layer and a scratch resistant wear layer the panels are ideally suited for wall cladding, especially outdoor.
  • the panels can also be used in kitchens, bathrooms, living areas and commercial spaces. Installation can be with mortar or tile glue and these products can be installed alongside stone and ceramic tiles.
  • the same product with an abrasion resistant wear layer is ideal for use as flooring panels.
  • a wooden decorative layer of thickness between 0.6 mm and 25 mm, and an abrasion resistant wear layer these panels would be a superior alternative to engineered wood floors.
  • Products of this invention are much more dimensionally stable and moisture vapour resistant than engineered wood floors. While using wood as the decorative layer, providing a thick decorative stratum allows consumers to re-sand and re-finish the flooring panels after every 4-5 years.
  • the flexibility in processing and dimensional stability extended by reinforced encapsulated composite panels also permit the use of a plurality of decorative layer combinations such as wood with metal inlays and vice versa, wood with leather, wood and metal with abalone inlays, pearl finish inlays, resin inlays and such. Products described in these embodiments can find use even in extreme service environments such as spas, saunas and swimming pool areas.
  • Reinforced encapsulated composite panels described in the preferred embodiment using cellulose-based panels, as foundation layer would find extensive application as wide plank flooring panels and as vapour resistant wall panels.
  • the exceptional dimensional stability and additional rigidity extended by the panels described in this embodiment permit the manufacture of large format panels.
  • Use of wider and longer flooring panels reduces the number of panel joints in the flooring as also dramatically augments the aesthetic appeal.
  • Panels described in this embodiment with wood veneer or wood slat decorative layers shall be superior alternatives to wide plank veneer floors and engineered wood floors respectively.

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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)
  • Finishing Walls (AREA)
  • Laminated Bodies (AREA)

Abstract

Les problèmes techniques posés par les panneaux actuellement disponibles sont les suivants : ils présentent des coefficients de dilatation élevés, ils ne présentent pas de stabilité structurelle et dimensionnelle, ils ne présentent pas résistance à l'eau et à la vapeur et ils bougent de manière significative en raison des changements de température et l'humidité. La solution à ces problèmes se présente sous la forme d'un panneau composite encapsulé renforcé utilisant des matériaux thermiquement stables, tels que la céramique, des carreaux de ciment, des panneaux de cellulose renforcés et de la pierre comportant des matériaux calorifuges tels que du bois dans le même panneau avec une interface d'encapsulation résistante à l'eau qui peut être poncée, étalonnée et usinée. Le panneau composite renforcé et encapsulé est ensuite recouvert d'une surface décorative, telle que du bois, un laminé, du cuir, du métal et une incrustation, puis recouvert de revêtements appropriés résistants aux égratignures et à l'abrasion. Ces panneaux peuvent trouver leur application en tant que parement mural et couvre-parquets.
PCT/IN2004/000021 2004-01-29 2004-01-29 Panneau composite encapsule renforce et procede de fabrication dudit panneau WO2005072957A1 (fr)

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Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN102275204A (zh) * 2011-08-25 2011-12-14 程治国 一种石木板及其生产工艺
ITMO20100272A1 (it) * 2010-09-30 2012-03-31 Priante Pelleitaliana S R L Manufatto per il rivestimento di superfici
WO2014111612A1 (fr) * 2013-01-21 2014-07-24 20030V | Valdetec Decoració E Interiorisme, S.L Carreau pour sols et murs
EP2871053A1 (fr) * 2013-11-08 2015-05-13 Piotr R. Tauferner Panneau renforcé résistant à l'eau
US9187899B2 (en) 2009-11-24 2015-11-17 Lg Hausys, Ltd. Composite panel and a production method therefor
EP3067198A1 (fr) * 2015-03-11 2016-09-14 M.J. International Flooring and Interior Products Inc. Tuile en chlorure de polyvinyle (pvc)
US10344469B2 (en) 2013-11-08 2019-07-09 Piotr Robert Tauferner Reinforced water-resistant board with traffic coat
EP2588311B2 (fr) † 2010-06-30 2020-03-25 Unilin, BVBA Panneau comprenant une couche composée polymère et une couche de renfort

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US4307140A (en) * 1980-07-31 1981-12-22 Davis Thomas E Abrasive resistant laminated article and method of manufacture
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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US9187899B2 (en) 2009-11-24 2015-11-17 Lg Hausys, Ltd. Composite panel and a production method therefor
EP2588311B2 (fr) † 2010-06-30 2020-03-25 Unilin, BVBA Panneau comprenant une couche composée polymère et une couche de renfort
ITMO20100272A1 (it) * 2010-09-30 2012-03-31 Priante Pelleitaliana S R L Manufatto per il rivestimento di superfici
EP2436515A1 (fr) * 2010-09-30 2012-04-04 Priante Pelleitaliana S.r.l. Produit de fabrication pour le recouvrement de surfaces
CN102275204A (zh) * 2011-08-25 2011-12-14 程治国 一种石木板及其生产工艺
WO2014111612A1 (fr) * 2013-01-21 2014-07-24 20030V | Valdetec Decoració E Interiorisme, S.L Carreau pour sols et murs
EP2871053A1 (fr) * 2013-11-08 2015-05-13 Piotr R. Tauferner Panneau renforcé résistant à l'eau
US9267285B2 (en) 2013-11-08 2016-02-23 Piotr Robert Tauferner Reinforced water-resistant board with traffic coat
US9719247B2 (en) 2013-11-08 2017-08-01 Piotr Robert Tauferner Reinforced water-resistant board with traffic coat
US10344469B2 (en) 2013-11-08 2019-07-09 Piotr Robert Tauferner Reinforced water-resistant board with traffic coat
EP3067198A1 (fr) * 2015-03-11 2016-09-14 M.J. International Flooring and Interior Products Inc. Tuile en chlorure de polyvinyle (pvc)

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