WO2019113768A1 - 一种具有硬质面层的镶嵌式复合地板块 - Google Patents

一种具有硬质面层的镶嵌式复合地板块 Download PDF

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Publication number
WO2019113768A1
WO2019113768A1 PCT/CN2017/115574 CN2017115574W WO2019113768A1 WO 2019113768 A1 WO2019113768 A1 WO 2019113768A1 CN 2017115574 W CN2017115574 W CN 2017115574W WO 2019113768 A1 WO2019113768 A1 WO 2019113768A1
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WIPO (PCT)
Prior art keywords
panel
substrate
degrees
tongue
groove
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PCT/CN2017/115574
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English (en)
French (fr)
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WO2019113768A9 (zh
Inventor
李林
Original Assignee
李林
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Application filed by 李林 filed Critical 李林
Priority to PCT/CN2017/115574 priority Critical patent/WO2019113768A1/zh
Priority to CN201780097669.9A priority patent/CN111512006A/zh
Publication of WO2019113768A1 publication Critical patent/WO2019113768A1/zh
Publication of WO2019113768A9 publication Critical patent/WO2019113768A9/zh

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    • 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

Definitions

  • the present invention relates to a floorboard (or floor panel) for forming a floor covering, in particular a mosaic floorboard having a hard and brittle layer, and more particularly to A mosaic composite floorboard with a side of the latching mechanism and a top layer of hard and brittle material.
  • floorboards can be joined to form a floor covering.
  • Commonly used floorboards include solid wood floorboards, laminated floorboards, ceramic tiles (glazed floor tiles), natural stone floor tiles, and the like.
  • Natural stone floor tiles are a kind of traditional high-grade floor materials, which have the advantages of high hardness, beautiful color and beautiful appearance. Tiles have similar characteristics to stone floor tiles, but are more polished and more rich than stone floor tiles. However, natural stone and ceramic tiles are mostly hard and brittle materials. In order to avoid breakage, usually the single piece size is small and the thickness is relatively large; the corners of the stone are easy to be bumped and damaged during installation; and because of the higher density and larger thickness Natural stone and tile will also weigh a lot.
  • the present invention provides a mosaic laminate flooring. Specifically, the present invention provides the following technical solutions.
  • the present invention provides a mosaic composite floorboard comprising a panel, a base plate and a first latching member for joining adjacent inlaid composite floorboards, the inner side of the first latching member being glued On the outer side surface of the substrate, the panel is covered and glued to the upper surface of the substrate and the upper surface of the first latching member, and the lower portion of the outer side surface of the substrate is contracted toward the inner surface of the substrate to form a concave surface.
  • a groove a lower portion of the inner side surface of the first latching member extends toward the substrate to form a convex portion that cooperates with the groove, and a top surface of the groove is disposed at a corresponding position of an upper surface of the convex portion
  • a second latching mechanism for preventing the top surface of the recess from translating with the upper surface of the projection.
  • the second latching mechanism includes an upwardly recessed card slot on the top surface of the recess and an upwardly convex position at the position corresponding to the upper surface of the convex portion and the card slot and the card Slotted card strips.
  • the second latching mechanism includes a downwardly projecting clip on the top surface of the recess and a downward recess at a position corresponding to the upper surface of the projection and the clip The card slot in which the card strip fits.
  • the second latching mechanism includes an upwardly recessed first slot on the top surface of the recess, and a downward recess at a position corresponding to the upper surface of the protrusion and the first slot a second card slot, and a card strip extending into the first card slot and the second card slot and cooperating therewith.
  • a top surface of the groove is glued to an upper surface of the convex portion; and, optionally, the card slot is glued to the card strip.
  • the inner side surface of the first latching member is inclined outward by 1-45 degrees, preferably 2-30 degrees, more preferably 3-15 degrees, such as 4-10 degrees, about 5 degrees, 6 degrees, 7 degrees, 8 Degree, 9 degrees.
  • one or more glue grooves are provided on an inner side surface of the first latching member and/or an outer side surface of the substrate.
  • the first latching member is selected from the group consisting of a tongue member and a tongue and groove member, the tongue member including a tongue extending outwardly from the outer side, the tongue and groove member including a tongue and groove extending inwardly from the outer side, An outer contour of the tongue is matched with an inner contour of the tongue to form an inlaid composite floorboard having the tongue member and an adjacent mosaic composite floorboard having the tongue and groove member
  • the tongue extension a first latching mechanism that enters the gutter, the first latching mechanism preventing mutual movement of adjacent two inlaid composite floorboards in a vertical direction and/or a horizontal direction.
  • tongue member and the tongue and groove member are respectively glued on the opposite and/or adjacent first side and second side of the substrate, the bottom of the tongue member and the tongue and groove
  • the bottoms of the components are fixedly connected to each other by a connecting strip.
  • the tongue member and the tongue and groove member are alternately glued on respective sides of the substrate; and the tongue member and the tongue and groove member are connected to each other.
  • the first latching member is glued to the outer side surface of the substrate in a continuous or intermittent manner.
  • the substrate is a convex polygon, and the first latching member surrounds each vertex of the convex polygon in a continuous manner, wherein the convex polygon is selected from three, four, five, six, seven, eight sides
  • the shape is preferably from positive three, four, five, six, seven, octagonal, more preferably from rectangular, more preferably from square, regular hexagon.
  • the panel is a rigid sheet selected from the group consisting of natural stone, ceramic, glass, quartz, artificial stone or metal.
  • the substrate is selected from the group consisting of a glass magnesium plate, a concrete plate, a thermoplastic plate, a thermosetting laminate, a honeycomb aluminum plate, a chipboard, a particle board, a MDF, a wood board, a wood plastic board, and a board formed by combining them.
  • the first latching member is a profile made of a material selected from the group consisting of aluminum or aluminum alloy, copper or copper alloy, iron or iron alloy, titanium or titanium alloy, thermoplastic, thermosetting plastic, composite material, wherein the thermoplastic
  • the plastic is selected from the group consisting of ABS resin, polyethylene, polypropylene, polysulfone resin, polycarbonate, polyphenylene ether, polyphenylene sulfide, polyacrylic resin, polyvinyl chloride resin, fluororesin, polyaryletherketone, polyphenyl ester, Polyoxymethylene, polyamide, and combinations thereof;
  • the thermosetting plastic is selected from the group consisting of a phenolic resin, a urea resin, a melamine resin, an unsaturated polyester resin, an epoxy resin, a silicone resin, a polyurethane, and combinations thereof; Resin-based composites reinforced from glass fibers, carbon fibers, boron fibers, graphite fibers, carbon nanotubes, graphene, whiskers,
  • the substantially surrounding first latching member is prepared by a method selected from the group consisting of casting, turning, forging, welding, riveting, 3D printing, powder molding, for plastic extrusion, Injection, casting, molding, lamination, 3D printing process, hand lay-up, jetting, filament winding, molding, pultrusion, RTM, autoclave, diaphragm, migration, reaction injection, soft film expansion , stamping and forming process.
  • the outer side of the first latching member faces outward beyond the outer side of the panel. Further, the outer side of the panel is inclined inwardly by 1-45 degrees, preferably 2-30 degrees, more preferably 3-15 degrees, such as 4-10 degrees, about 5 degrees, 6 degrees, 7 degrees, 8 degrees, 9 degrees. . Further, the oblique side of the outer side of the panel extends downwardly through the glue layer between the panel and the first latching member. Further, the upper surface of the first latching member is provided with a glue groove.
  • the present invention provides a floor formed by assembling the inlaid composite floorboard according to any of the above, wherein the first latching members of adjacent inlaid composite floorboards cooperate to form a first Lock mechanism.
  • the adjacent panels of the adjacent inlaid composite floorboards do not touch each other and are filled with a joint glue.
  • the present invention provides an intermediate member for preparing the inlaid composite floorboard according to any of the above, comprising the first latching member and an upper portion from the first latching member An outer portion of the outer edge extending outwardly to form a baffle, the inner side of the baffle being inclined outwardly by 1-45 degrees, preferably 2-30 degrees, more preferably 3-15 Degrees, for example, 4-10 degrees, about 5 degrees, 6 degrees, 7 degrees, 8 degrees, 9 degrees.
  • an upper surface of the protruding portion is flush with an upper surface of the first latching member or an upper surface of the protruding portion is inclined outward and downward.
  • first latching member and the protruding portion are integrally formed or assembled; preferably, the assembly molding is selected from the group consisting of welding, snap connection, bonding, plugging, and pinhole connection.
  • the present invention provides a method of preparing the mosaic-type nuclear floorboard according to any of the above, comprising:
  • Step 000 providing the panel, the substrate, and the first latching member
  • Step 100 applying a first glue on an outer side surface of the substrate and/or an inner side surface of the first latching member in the middle member, and an outer side surface of the substrate and the first latching member
  • the inner side surfaces are mated and bonded together such that a top surface of the groove and a corresponding position of the upper surface of the convex portion are formed to prevent the top surface of the groove from interfacing with the upper surface of the convex portion a second locking mechanism that translates;
  • Step 200 on an upper surface of the substrate and an upper surface of the first latching member, and/or the panel A second glue is coated on the lower surface, and the lower surface of the panel is fitted and bonded to the upper surface of the substrate and the upper surface of the first latching member.
  • step 100 a first glue is applied on the upper surface of the convex portion and/or the top surface of the groove, and the upper surface of the convex portion and/or the top surface of the groove is Bonded together.
  • the panel is provided by a face-to-face panel, the first latching member being provided by the intermediate member according to any one of claims 23-25, wherein the size of the panel original panel is greater than or equal to The size of the panel is less than or equal to the size of the space defined by the inner side of the baffle of the intermediate member;
  • step 200 a second glue is applied on an upper surface of the substrate and an upper surface of the first latching member, and/or a lower surface of the panel original plate, and the panel original plate is placed in the a space defined by an inner side of the baffle of the intermediate member, and the lower surface of the original plate of the panel is mated and bonded to the upper surface of the substrate and the upper surface of the first latching member;
  • the method further includes: step 300, removing the baffle of the middle piece and a portion of the original panel of the panel more than the panel. Further, in step 300, the removing is performed by a method selected from the group consisting of grinding, milling, cutting, sawing, and combinations thereof. Further, pressure is applied in step 100 and/or step 200 to compress the first latching member or intermediate member, the panel or panel blank, and the substrate together. Further, the first latching member or intermediate member, the panel or panel original plate, the substrate, and the first glue and/or the second glue are heated in step 100 and/or step 200.
  • the examples are generally described by a certain range, and are merely for the sake of clarity and clarity, and are not intended to limit the invention.
  • the range of description includes sub-ranges and all individual values within this range.
  • the range of 1 to 6, including sub-ranges such as 1 to 3, 1 to 4, 1 to 5, 2 to 4, 2 to 6, 3 to 6, etc. also includes individual values within the range, such as 1, 2 , 3, 4, 5, 6.
  • the inlaid composite floorboard of the present invention locks the relative position between the first latching member and the substrate by using a second latching mechanism, avoiding the top surface of the groove and the upper surface of the convex portion
  • the mutual translation between them ensures the dimensional accuracy of the floorboard, which not only improves the yield and production efficiency in the manufacturing process, but also further reduces the deformation of the floorboard during use.
  • the inlaid multi-core floorboard of the invention fully guarantees the decoration effect of high-hardness floor materials such as natural stone, and has high strength, light weight, can be directly spliced, does not require auxiliary materials such as cement, and is not easily damaged during installation.
  • the advantages of high safety, greatly improve work efficiency, save production costs, are especially suitable for manual installation, and can save a lot of installation labor costs and auxiliary materials, etc., which is especially beneficial for DIY enthusiasts who do their own hands-on installation.
  • FIG. 1 is a schematic cross-sectional structural view of a mosaic composite floorboard according to the present invention.
  • FIG. 2 is a schematic structural view of a frame in a mosaic type nuclear floorboard according to the present invention.
  • FIG. 3 is a schematic cross-sectional structural view of a mosaic composite floorboard according to another embodiment of the present invention.
  • FIG. 4 is a schematic structural view of a frame in a mosaic type nuclear floorboard according to another embodiment of the present invention.
  • Figure 5 is an enlarged view of a portion A of Figure 1;
  • FIG. 6 is a schematic structural view of an outer side surface of a mosaic type nuclear floorboard according to another embodiment of the present invention.
  • Figure 7 is a schematic structural view of a floor covering assembled by the inlaid composite floorboard shown in Figure 1;
  • Figure 8 is a schematic view showing the structure of the tongue member intermediate member (a) and the tongue and groove member intermediate member (b) for preparing the inlaid composite floorboard shown in Figure 1;
  • Figure 9 is a schematic view showing the processing state of the method for preparing the inlaid composite floorboard shown in Figure 1;
  • Figure 10 is a schematic view of the processing state of steps 810-840;
  • Figure 11 is a schematic view showing the processing state of the step 850.
  • Figure 12 is a schematic view showing the structure of some latching mechanisms applicable to the mosaic type floorboard of the present invention.
  • the mosaic laminate floor panel of the present invention includes a panel 6, a substrate 1 and a first latching member (including a tongue member 2 and a tongue and groove member 3) for joining adjacent mosaic laminate flooring blocks.
  • the inner side surface of the first latching member (including the first inclined surface 201 and the second inclined surface 301) is inclined outward, and the inclination angle (the first inclined surface angle 202 and the second inclined surface inclination angle 302) is 1-45 degrees, preferably 2-30.
  • the degree is more preferably 3-15 degrees, for example 4-10 degrees, about 5 degrees, 6 degrees, 7 degrees, 8 degrees, 9 degrees.
  • the inner side of the first latching member is glued to the outer side of the substrate 1 through the substrate bonding layer 8.
  • the panel 6 is covered and bonded to the upper surface of the substrate 1 through the panel bonding layer 7 and The upper surface of the first latching member (including the tongue member 2 and the tongue and groove member 3).
  • the upper surface of the first latching member including the tongue member 2 and the tongue and groove member 3.
  • the inner side surface of the first latching member is inclined outward such that the upper edge of the first latching member defines a size larger than the size of the substrate 1, in the production process of the floorboard It is easier to assemble the substrate 1 with the first latching member, which can significantly reduce the defects of the substrate 1 misplaced on the upper surface of the first latching member.
  • a lower portion of the outer side surface of the substrate 1 is recessed toward the inside of the substrate 1 to form a groove, and a lower portion of the inner side surface of the first latching member extends toward the substrate 1 to form a convex portion that cooperates with the groove.
  • a second latching mechanism for preventing a top surface of the recess from interchanging with an upper surface of the convex portion is provided at a corresponding position of a top surface of the groove and an upper surface of the convex portion.
  • the second latching mechanism includes an upwardly recessed card slot (including the first card slot 12 and the second card slot 13) on the top surface of the recess and an upper surface of the protrusion
  • a card strip (including a first card strip 203 and a second card strip 303) that protrudes upward and is engaged with the card slot at a position corresponding to the card slot.
  • the top surface of the groove is glued to the upper surface of the protrusion; and the card slot is glued to the card strip.
  • the cross-sectional profile of the card slot and the card strip is trapezoidal, triangular, rectangular, wavy, curved, and the like.
  • the card slot has a depth of 2-8 mm, such as 3-7 mm, 4-6 mm, about 5 mm, etc.; the opening width is 2-8 mm, such as 3-7 mm, 4-6 mm, about 5 mm, and the like.
  • the height of the strip is 1-5 mm, such as 2-4 mm, about 3 mm, etc., and the bottom width is 1-5 mm, such as 2-4 mm, about 3 mm, and the like.
  • the card strip and the card slot cooperate with each other to form a second latching mechanism, which effectively prevents the top surface of the groove from translating with the upper surface of the convex portion, thereby ensuring the dimensional accuracy of the floor block, not only in manufacturing
  • the process improves the yield and production efficiency, and further reduces the deformation of the floorboard during use.
  • a third adhesive groove 32 is disposed on the inner side surface of the first latching member, and a plurality of first adhesive grooves 11 are disposed on the outer side surface of the substrate 1.
  • these glued grooves increase the capacity of the wedge-shaped grooves, which is advantageous for reducing the pressure generated by the excess glue
  • the inner side of the first bonding member and the outer side of the first locking member 8 are added to the substrate bonding layer 8 Bond strength.
  • the upper surface of the first latching member is also provided with a second adhesive groove 31 for accommodating excess glue of the bonding surface layer 6, and the lower surface of the opposite layer 6 of the panel bonding layer 7 and the first card are added. The bond strength of the upper surface of the lock member.
  • the first latching member includes a tongue member 2 and a tongue and groove member 3 disposed on opposite outer sides of the substrate, the tongue member 2 including a tongue 4 extending outwardly from the outer side, the tongue and groove member 3 comprising a tongue and groove 5 extending inwardly from the outside, the outer contour of the tongue 4 matching the inner contour of the tongue and groove 5 to bring the mosaic composite floorboard with the tongue member 2 adjacent
  • a first latching mechanism is formed between the inlaid composite floorboards having the tongue and groove members 3 and extending into the tongue and groove 5, the first card locking machine
  • the structure prevents mutual movement of adjacent two inlaid composite floorboards in the vertical direction and/or the horizontal direction.
  • the tongue member 2 and the tongue and groove member 3 are alternately bonded on respective sides of the substrate 1, and the tongue member 2 and the tongue and groove member 3 are connected to each other.
  • the tongue member 2 and the tongue and groove member 3 are elongated profiles made of metal (selected from aluminum or aluminum alloy, copper or copper alloy, iron or iron alloy including stainless steel, etc.) (in other embodiments, It may be a long strip made of thermoplastic, thermosetting plastic, fiber reinforced composite material (including reinforced composite materials such as carbon fiber, glass fiber, metal fiber, mineral fiber, carbon nanotube, etc.);
  • the tongue member 2 includes The tongue 4, the tongue and groove member 3 includes a tongue and groove member 5, and the two pairs of tongue member 2 and the tongue and groove member 3 are each disposed oppositely and in parallel such that a portion of the tongue member 2 other than the tongue 4 forms a groove member 3 a square frame having a side length of 200-1600 mm, preferably 300-400 mm, 500-600 mm, 700-800 mm, 900-1000 mm, 1
  • the bottom surface of the tongue 4 and the gutter 5 facing the inside of the frame extends toward the center of the frame to form a support portion.
  • the bottom surface of the support portion is flush with the bottom surface of the frame.
  • the thickness of the support portion can be selected according to the size of the floor block. Usually, the thickness is 0.8-2 mm, for example, 0.9-1 mm, 1.1-1.2 mm, 1.3-1.5 mm, 1.6-1.8 mm, etc.; the width of the support portion can be arbitrarily selected, and the wider the reinforcement of the substrate, the greater the degree, but The cost will also increase, and the width is usually 2-30 mm, such as 4-6 mm, 8-12 mm, 14-16 mm, 18-20 mm, 25-30 mm, and the like.
  • the substrate 1 is placed inside the frame, and the outer contour of the substrate 1 is matched to the inner contour of the frame Match.
  • the substrate 1 is selected from the group consisting of a glass magnesium plate (also referred to as: a magnesium oxide plate, an MGO plate, etc.), a concrete plate (which may optionally include a light ceramsite or a foamed cement mortar), a thermoplastic plate, a thermosetting laminate, a honeycomb aluminum plate, Those having a medium density such as chipboard, particle board, MDF, wood board, etc., such as those having a density of 3 g, 2.5 g, 2 g, 1.5 g, 1 g, 0.8 g, 0.6 g, etc. per cubic centimeter.
  • the substrate 1 may be a composite substrate formed by laminating various sheets selected from the above.
  • the substrate 1 further includes one or more of a cork pad, a rubber underlayer, a waterproof backing layer, and the like attached to the bottom surface of the substrate 1.
  • fibers for example, glass fibers, carbon fibers, mineral fibers, metal fibers, organic polymer material fibers, etc.
  • the bottom surface of the substrate 1 is flush with the bottom surface of the frame, the upper surface is flush with the upper surface of the frame, and the total thickness of the substrate 1 is consistent with the thickness of the frame, typically 5-20 mm, such as 6-7 mm, 7.5-8.5 mm. , 9-11 mm, 12-15 mm, etc.
  • the bottom edge of the substrate 1 is also provided with a recess for receiving a support portion of the frame that matches the outer contour of the support plate.
  • at least one of the boards 1 is composed of a plurality of horizontally assembled sub-boards with a reserved gap between the sub-boards to accommodate deformation of the substrate 1 beyond the frame.
  • the side wall of the substrate 1 is connected to the inner wall of the frame composed of the tongue member 2 and the tongue and groove member 3 through the substrate bonding layer 8, and the inner wall of the groove at the bottom edge of the substrate 1 is supported by the substrate bonding layer 8 and the frame.
  • the upper surface of the part is connected.
  • a glue groove 32 is provided on the inner wall of the frame
  • a glue groove 31 is provided on the upper surface of the support portion of the frame
  • a glue groove is provided on the side wall of the substrate 1.
  • a glue groove 11 is formed on the inner wall of the groove at the bottom edge of the substrate 1, and the glue layer 8 extends into the glue grooves, thereby remarkably enhancing the connection strength between the substrate 1 and the frame.
  • the panel 6 is joined to the upper surface of the substrate 1 and the frame composed of the tongue member 2 and the tongue and groove member 3 through the panel bonding layer 7.
  • the panel 6 is a high-hardness sheet, particularly a high-hardness brittle sheet selected from a sheet made of stone (including natural stone and artificial stone, preferably natural stone), ceramic, glass or metal (for example, stainless steel, etc.).
  • the thickness of the panel 6 can be any suitable thickness, such as 1-10 mm, 1.2-8 mm, 1.5-5 mm, 2-4 mm, about 3 mm, and the like.
  • the upper surface of the frame is provided with a glue groove 33, thereby significantly enhancing the strength of the connection between the panel 6 and the substrate 1 and the frame.
  • the width of the mouth of one or more of the above respective bonding grooves is slightly smaller than the width of the bottom, for example, the width of the mouth is 60-99%, 70-95%, 80-90%, etc. of the width of the bottom; Further reinforcement The strength of the connection between the board 1 and the frame.
  • the mouth width of one or more of the above respective bonding grooves is 0.5-5 mm, such as 0.6-4 mm, 0.8-3 mm, 1-2 mm, etc., and the depth of the bonding groove is 0.2. - 2 mm, for example 0.25-1.5 mm, 0.3-1 mm, 0.35-0.8 mm, 0.4-0.6 mm, about 0.5 mm, and the like.
  • any number of glue grooves such as 1-5 glue grooves, may be provided as needed throughout the above.
  • the tongue member 2 and the tongue and groove member 3 are glued respectively on the opposite and/or adjacent first side and second side of the substrate 1, the tongue member 2
  • the bottom of the groove and the bottom of the tongue and groove member 3 are fixedly connected to each other by a connecting strip 230.
  • the first latching member is glued to the outer side of the rectangular substrate 1 in a continuous or intermittent manner, wherein the tongue structure 2 on the outer side of one side of the substrate 1 comprises a plurality of segments, The segments are connected by a tongue connector 204; the tongue and groove structure 3 on the outer side of the other side of the substrate 1 comprises a plurality of segments, each segment being connected by a tongue and groove connector 304; on the substrate 1
  • One ends of the two first latching members on the adjacent two sides of one corner are fixedly coupled to each other to surround the corners, and the other ends of the respective ends are fixedly coupled to each other by the connecting strips 230.
  • the façade 21 on which the outer side of the first latching member is located extends outwardly beyond the outer side 62 of the panel.
  • the outer side of the panel is inclined inwardly by 1-45 degrees, preferably 2-30 degrees, more preferably 3-15 degrees, such as 4-10 degrees, about 5 degrees, 6 degrees, 7 degrees, 8 degrees. 9 degrees.
  • the slanted side of the outer side of the panel extends downwardly through the glue layer between the panel and the first latching member.
  • the four sides of the panel 6 each have a panel outer side 62 that is inclined from the bottom to the center of the panel 6.
  • the angle 63 between the slope and the facade 21 where the side walls of the frame are located is 3-45 degrees.
  • the panel outer side 62 extends downwardly through or through the panel bonding layer 6 and the facade 21 or
  • the side walls themselves intersect but do not intersect the tongue 4 or the tongue and groove 5.
  • the panel outer side 62 extends downwardly into the panel bonding layer 6, it intersects the facade 21 on which the side wall of the frame is located; when the panel outer side 62 extends downward through the panel bonding layer 6, it continues to extend.
  • the frame Through the frame, it will intersect the side wall of the frame; especially when the panel outer side 62 extends downward through the panel bonding layer 6, it can also be just the upper outer edge of the side wall of the frame intersect.
  • the panel outer side surface 62 thus provided can significantly avoid the damage caused by the collision of the panels 6 when the floor panels are assembled, and allows a certain floorboard to be fixed during the assembly process.
  • the angle of inclination is spliced with another floorboard, thereby greatly reducing the damage of the floorboard during installation, and significantly improving the installation efficiency and reducing the labor intensity of the installation.
  • the panel outer side 62 can also be contracted inwardly and substantially parallel with the façade 21, thereby avoiding damage caused by the collision of the panels 6 when the floor panels are assembled.
  • the panel outer side 62 and the upper portion of the panel glue layer 7 collectively contract inwardly, which facilitates removal of a portion of the panel outer side 62 such that the panel outer side 62 is located inside the facade 21.
  • the rim at the intersection of the upper surface of the panel 6 and the outer side surface 62 of the panel has a chamfer 61 having a radius of 0.5-20 mm, preferably 1-15 mm, such as 0.6-4. Millimeter, 0.7-3 mm, 0.8-2 mm, about 1 mm, and the like. Setting the chamfer can significantly reduce the damage to the ribs during installation and effectively avoid sharp edges that can cut the installer.
  • the first latching members of the adjacent inlaid composite floorboards cooperate to form a first latching mechanism, and the adjacent ones are adjacent
  • the panels of the inlaid composite floorboard do not touch each other and are filled with a joint glue 64.
  • the tongue 4 of one of the floorboards is inserted into the tongue and groove 5 of the other floorboard, and the panels 6 of the two floorboards are not in contact with each other.
  • the slits formed by the respective inclined faces 63 are joined with a certain elasticity and waterproofing joint glue 64, such as epoxy glue, etc., thereby preventing the water leakage while allowing the panels 6 to expand without each other. A collision occurs and the seal to the gap is maintained while contracting.
  • the various adhesive layers and the glue used for the joint adhesive may be any of those known in the art to be applicable, such as epoxy glue, polyurethane glue and the like.
  • the mosaic type nuclear floor block of the invention fully guarantees the decoration effect of the high hardness floor material such as natural stone, and has high strength, light quality, direct splicing, no auxiliary materials such as cement, and is not easy to be damaged and safely installed. High-quality advantages, especially suitable for manual installation, and a large number of savings in labor costs and accessories, etc., for their own hands-on installation of DIY enthusiasts.
  • FIG 8 is a schematic view showing the structure of a tongue member intermediate member (a) and a tongue and groove member intermediate member (b) for preparing the inlaid composite floorboard of the present invention, wherein the tongue member intermediate member comprises a tongue member 2, The upper outer edge of the tongue member 2 extends substantially horizontally outwardly to form a projection 34, and the outer end of the extension portion 35 extends substantially vertically upwardly to form a first flap 36; the tongue and groove member intermediate member includes a tongue and groove member 3.
  • the projecting portion 35 formed from the upper outer edge of the tongue and groove member 3 extending substantially horizontally outward, and the outer end of the self-extending portion 35 is substantially
  • the second baffle 37 is formed to extend vertically upward.
  • the inner side surface of the first baffle 36 is outwardly inclined to become a third inclined surface 361, and the inner side surface of the second baffle 37 is outwardly inclined to become a fourth inclined surface 371, a third inclined surface angle 362 of the third inclined surface 361, and a fourth inclined surface
  • the fourth bevel angle 372 of 371 is 1 to 45 degrees, preferably 2 to 30 degrees, more preferably 3 to 15 degrees, such as 4 to 10 degrees, about 5 degrees, 6 degrees, 7 degrees, 8 degrees, and 9 degrees.
  • the upper surfaces of the first projecting portion 34 and the second projecting portion 35 are flush with the upper surface of the first latching member or are inclined outward and downward.
  • the tongue structure 2 in the first latching member, the first protruding portion 34 and the first baffle 36 are integrally formed or assembled; the tongue and groove structure 3 in the first latching member, the The second projecting portion 35 and the second baffle 37 are integrally formed or assembled.
  • the assembly molding is selected from the group consisting of welding, snap connection, bonding, plugging, and pin hole connection.
  • FIG. 9 is a schematic view showing the processing state of the method for preparing the inlaid composite floorboard shown in FIG. 1, and the corresponding method for preparing the root includes:
  • Step000 providing the panel 6, the substrate 1 and the first latching member (the tongue member 2 and the tongue and groove member 3);
  • Step 100 applying a first glue 9 on an outer side surface of the substrate 1 and/or an inner side surface of the first latching member in the middle member, and an outer side surface of the substrate 1 and the first card
  • the inner side surfaces of the lock members are fitted and bonded to each other such that a top surface of the groove and a corresponding position of the upper surface of the convex portion form a top surface and the convex portion for preventing the groove a second latching mechanism that translates the upper surfaces to each other;
  • Step 200 applying a second glue 10 on the upper surface of the substrate 1 and the upper surface of the first latching member, and/or the lower surface of the panel 6, and the lower surface of the panel 6 is The upper surface of the substrate 1 and the upper surface of the first latching member are fitted and bonded to each other.
  • the wedge-shaped groove which gradually becomes larger from the bottom to the upper side is formed therebetween, and the wedge-shaped groove can accommodate the glue
  • the excess glue is connected; the invention significantly reduces the pressure of the excess glue on the inner side of the first latching member and the outer side of the substrate 1 compared to the case of not tilting outward, and improves the dimensional accuracy of the floorboard The deformation is reduced, and the production efficiency and yield of the floorboard are advantageously improved.
  • the inner side surface of the first latching member is inclined outwardly such that the upper edge of the first latching member defines a size larger than the size of the substrate 1, and the substrate 1 and the first latching member are more easily assembled during the production of the floorboard. Together, the defects of the substrate 1 misplaced on the upper surface of the first latching member can be significantly reduced.
  • the card strip and the card slot cooperate with each other to form a second latching mechanism, which effectively prevents the top surface of the groove from translating with the upper surface of the convex portion, thereby ensuring the dimensional accuracy of the floor block, not only in manufacturing
  • the process improves the yield and production efficiency, and further reduces the deformation of the floorboard during use.
  • a third adhesive groove 32 is disposed on the inner side surface of the first latching member, and a plurality of first adhesive grooves 11 are disposed on the outer side surface of the substrate 1.
  • these glued grooves increase the capacity of the wedge-shaped grooves, which is advantageous for reducing the pressure generated by the excess glue
  • the inner side of the first bonding member and the outer side of the first locking member 8 are added to the substrate bonding layer 8 Bond strength.
  • the upper surface of the first latching member is also provided with a second adhesive groove 31 for accommodating excess glue of the bonding surface layer 6, and the lower surface of the opposite layer 6 of the panel bonding layer 7 and the first card are added. The bond strength of the upper surface of the lock member.
  • step 100 a first glue 9 is applied on the upper surface of the convex portion and/or the top surface of the groove to bond the upper surface of the convex portion and/or the top surface of the groove Together.
  • the panel 6 is provided by a facet plate 65, the first latching member being provided by the intermediate piece, wherein the size of the panel original plate 65 is greater than or equal to the size of the panel 6. And less than or equal to the size of the space defined by the inner sides of the first baffle 36 and the second baffle 37 of the intermediate member;
  • a second glue 10 is applied on the upper surface of the substrate 1 and the upper surface of the first latching member, and/or the lower surface of the panel original plate 65, and the panel original plate 65 is a space defined by an inner side surface of the first baffle 36 and the second baffle 37 of the intermediate member, and a lower surface of the panel original plate 65 and an upper surface of the substrate 1 and the first latch
  • the upper surfaces of the members are mated and bonded together;
  • the method further includes:
  • Step 300 removing the first baffle 36 and the second baffle 37 of the middle piece and the first protrusion 34, the second protrusion 35, and the portion of the panel original plate 65 that are more than the panel 6
  • the removal is performed by a method selected from the group consisting of grinding, milling, cutting, sawing, and combinations thereof.
  • the third slope 361 of the first baffle 36 and the fourth slope 371 of the second baffle 37 cause the first baffle 36 and the second baffle 37 to define a space that tapers from top to bottom, facilitating the panel
  • the original plate 65 is conveniently placed on the upper surface of the substrate 1 at the bottom of the space to avoid
  • the panel original plate 65 close to the space size is liable to rest on the first baffle 36 and the second baffle 37; and it is advantageous to remove the remaining glue from the outer side of the panel original plate 65 with the third bevel 361 and the
  • the wedge-shaped grooves formed by the four inclined faces 271 are respectively discharged at a lower pressure to avoid the problem of deformation of the first latching member caused by the pressure, thereby further improving the dimensional accuracy and uniformity of the floorboard.
  • step 100 and/or step 200 applying pressure in step 100 and/or step 200 causes the first latching member or intermediate member, the panel or panel original plate, and the substrate to be pressed together, and in step 100 and/or step 200 Heating the first latching member or intermediate member, the panel or panel original plate, the substrate, and the first glue and/or the second glue.
  • the method for preparing the mosaic-type floorboard block of the present invention comprises:
  • Step 500 providing a tongue member intermediate member and a tongue and groove member intermediate member as shown in FIG. 8, a substrate 1 and a panel original plate 65, the panel original plate 65 having a size slightly larger than the size of the panel 6;
  • Step 600 forming an intermediate frame including the frame shown in FIG. 2 by using the two tongue member intermediate members of the step 500 and the two tongue and groove member intermediate members according to the size of the required floorboard;
  • Step 700 applying a first glue 9 on the inner wall of the side wall and the bottom edge groove of the substrate 1 and/or the inner side wall and the upper surface of the middle frame of the step 600, and then placing the substrate 1 into the intermediate frame, Keeping the bottom surface of the substrate 1 flush with the bottom surface of the intermediate frame until the first glue 9 is cured to form the substrate bonding layer 8;
  • Step 800 applying a second glue 10 on the upper surface of the substrate 1 and the upper surface of the intermediate frame after performing step 700, and then placing the panel original plate 65 on the second glue 10 and the space enclosed by the baffle 61 Until the second glue 10 is cured to form the panel bonding layer 7, to obtain a floor block intermediate;
  • Step 900 in the floor block intermediate body, the protruding portion 34-35, the baffle 36-37, and the excess portion of the panel original plate 65 are removed along the elevation surface 21 and the panel outer side surface 62 to obtain the mosaic type nuclear floorboard block. .
  • the method further includes, between step 800 and step 900,
  • Step 810 providing a second set of two tongue member intermediate members and two tongue and groove member intermediate members as shown in Figure 8, and the substrate 1;
  • Step 820 forming an intermediate frame including the frame shown in FIG. 2 by using the two tongue member intermediate members of the step 810 and the two tongue and groove member intermediate members according to the size of the required floor panel;
  • Step 830 on the inner wall of the side wall and bottom edge groove of the substrate 1 of step 810 and/or in step 820
  • the inner side wall and the bottom upper surface of the intermediate frame are coated with the first glue 9, and then the substrate 1 is placed in the intermediate frame, and the bottom surface of the substrate 1 is kept flush with the bottom surface of the intermediate frame until the first glue 9 is solidified to form a substrate.
  • Step 840 applying a second glue 10 on the upper surface of the substrate 1 and the upper surface of the intermediate frame in step 830, and then placing the other side of the panel original plate 65 of step 800 on the second leg 10 and surrounding the baffle 61 In the space, until the second glue 10 is cured to form the panel glue layer 7;
  • step 850 the panel original panel 65 after step 840 is separated from the center along the horizontal separating surface 66 to obtain two floor panel intermediates.
  • the first glue 9 and the second glue 10 are each selected from any suitable glue in the prior art, such as epoxy glue and polyurethane glue, etc., and the curing thereof is carried out under the conditions provided by the supplier or under known conditions. .
  • the structure of the tongue member intermediate member and the tongue and groove member intermediate member in the latching mechanism may be selected from the paired structures A1-A2, B1-B2, C1-C2 shown in FIG. Any one of D1-D2, E1-E2, F1-F2, G1-G2 to form a latching mechanism suitable for a variety of different needs, wherein the dashed lines show the extensions included in each pair of intermediate members The position where the outlet portion 34-35 and the baffle 36-37 are separated from the tongue member and the tongue and groove member (corresponding to the elevation surface 21); in addition, the tongue member and the groove member are glued to the wall surface of the substrate and the panel There is a glue groove.

Abstract

一种镶嵌式复合地板块，包括面板（6）、基板（1）和用于连接相邻的镶嵌式复合地板块的第一卡锁构件，所述第一卡锁构件的内侧面胶接于所述基板（1）的外侧面，所述面板（6）覆盖并胶接于所述基板（1）的上表面和所述第一卡锁构件的上表面，所述基板（1）的外侧面的下部向所述基板（1）内部收缩形成凹槽，所述第一卡锁构件的内侧面的下部向所述基板（1）延伸形成与所述凹槽配合的凸部，所述凹槽的顶面与所述凸部的上表面的对应位置处设有用于阻止所述凹槽的顶面与所述凸部的上表面相互平移的第二卡锁机构。镶嵌式复合地板块利用第二卡锁机构保证了地板块的尺寸精度，不但在制造过程中提高了成品率和生产效率，在使用过程中也能进一步地减小地板块的变形。

Description

一种具有硬质面层的镶嵌式复合地板块 技术领域
本发明涉及一种用于形成地板覆层的地板块(或称为：地板镶板，floor panel)，尤其是已知具有硬脆面层的镶嵌式复合地板块，更具体地，涉及一种具有卡锁机构的侧边和硬脆材料的面层的镶嵌式复合地板块。
背景技术
众所周知，可以将地板块通过拼接形成地板覆层。常用的地板块包括实木地板块、层压地板块、瓷砖(釉面地板砖)、天然石材地板砖等。天然石材地板砖是一种传统的高档地板材料，具有高硬度、色泽花纹美观大方等优点。瓷砖具有与石材地板砖类似的特点，但比石材地板砖更加光洁，花纹更加丰富。然而，天然石材和瓷砖大都属于硬脆材质，为避免折损，通常单块尺寸较小，厚度也比较大；安装时石材的边角容易磕碰而损坏；又由于密度较高，厚度较大的天然石材和瓷砖的重量也会很大。再者，对于一些高档、稀缺的天然石材，纯粹的天然石材地板砖成本会过于高昂。此外，传统上天然石材地板和瓷砖地板块铺装时都需要使用大量的灰浆，例如水泥等，得天然石材和瓷砖的铺装需要大量的劳力和建筑材料。随着经济的发展，人工成本逐渐增加，尤其在发达国家和地区，天然石材地板和瓷砖的以上缺点极大地限制了其应用。
近年来，有人将天然石材作为面层贴附在轻质基材上，制成了复合地板。然而这些复合地板仍然存在大量的问题。例如，轻质基材与石材面层之间因膨胀系数不同而容易脱落开裂，轻质基材强度较低且容易变形而造成石材面层折断，轻质基材本体作为企口连接部件由于强度不足、尺寸精度较低而导致铺装的地板平整度下降。
因此，仍然需要开发新型的具有硬质面层的镶嵌式复合地板。
发明概述
技术问题
问题的解决方案
技术解决方案
为解决上述技术问题，本发明提供了一种镶嵌式复合地板。具体而言，本发明提供以下技术方案。
在一个方面，本发明提供一种镶嵌式复合地板块，包括面板、基板和用于连接相邻的镶嵌式复合地板块的第一卡锁构件，所述第一卡锁构件的内侧面胶接于所述基板的外侧面，所述面板覆盖并胶接于所述基板的上表面和所述第一卡锁构件的上表面，所述基板的外侧面的下部向所述基板内部收缩形成凹槽，所述第一卡锁构件的内侧面的下部向所述基板延伸形成与所述凹槽配合的凸部，所述凹槽的顶面与所述凸部的上表面的对应位置处设有用于阻止所述凹槽的顶面与所述凸部的上表面相互平移的第二卡锁机构。
进一步地，所述第二卡锁机构包括位于所述凹槽顶面的向上凹陷的卡槽和位于所述凸部上表面与所述卡槽对应的位置处的向上凸起且与所述卡槽配合的卡条。
进一步地，所述第二卡锁机构包括位于所述凹槽顶面的向下凸起的卡条和位于所述凸部上表面与所述卡条对应的位置处的向下凹陷且与所述卡条配合的卡槽。
进一步地，所述第二卡锁机构包括位于所述凹槽顶面的向上凹陷的第一卡槽、位于所述凸部上表面与所述第一卡槽对应的位置处的向下凹陷的第二卡槽，以及伸入所述第一卡槽和第二卡槽并与其配合的卡条。
进一步地，所述凹槽的顶面胶接于所述凸部的上表面；并且，任选地，所述卡槽胶接于所述卡条。进一步地，所述第一卡锁构件的内侧面向外倾斜1-45度，优选2-30度、更优选3-15度，例如4-10度、约5度、6度、7度、8度、9度。进一步地，所述第一卡锁构件的内侧面和/或所述基板的外侧面上设有一个或更多个胶接槽。
进一步地，所述第一卡锁构件选自榫舌构件和榫槽构件，所述榫舌构件包括从外侧面向外延伸的榫舌，所述榫槽构件包括从外侧面向内延伸的榫槽，所述榫舌的外部轮廓与所述榫槽的内部轮廓相匹配以使具有所述榫舌构件的镶嵌式复合地板块与相邻的具有所述榫槽构件的镶嵌式复合地板块之间形成所述榫舌伸 入所述榫槽的第一卡锁机构，所述第一卡锁机构阻止相邻的两个镶嵌式复合地板块在垂直方向上和/或水平方向上的相互移动。
进一步地，在所述基板的相对和/或相邻的第一侧面和第二侧面上分别胶接所述榫舌构件和所述榫槽构件，所述榫舌构件的底部与所述榫槽构件的底部之间通过连接条相互固定连接。
进一步地，在所述基板的各个侧面上交替地胶接所述榫舌构件和所述榫槽构件；并且所述榫舌构件和所述榫槽构件相互连接。进一步地，所述第一卡锁构件以连续或断续的方式胶接于所述基板的外侧面。进一步地，所述基板是凸多边形，所述第一卡锁构件以连续的方式包围所述凸多边形的各个顶角，其中所述凸多边形选自三、四、五、六、七、八边形，优选自正三、四、五、六、七、八边形，更优选自矩形，更优选自正方形、正六边形。
进一步地，所述面板为硬质薄板，选自由天然石材、陶瓷、玻璃、石英、人造石材或金属制成的薄板。进一步地，所述基板选自玻镁板、混凝土板、热塑性塑料板、热固性层板、蜂窝铝板、粗纸板、刨花板、密度板、木板、木塑板及其相互组合形成的板。
进一步地，所述第一卡锁构件是由选自铝或铝合金、铜或铜合金、铁或铁合金、钛或钛合金、热塑性塑料、热固性塑料、复合材料制成的型材，其中所述热塑性塑料选自ABS树脂、聚乙烯、聚丙烯、聚砜树脂、聚碳酸酯、聚苯醚、聚苯硫醚、聚丙烯酸树脂、聚氯乙烯树脂、氟树脂、聚芳醚酮、聚苯酯、聚甲醛、聚酰胺及其组合；所述热固性塑料选自酚醛树脂、脲醛树脂、三聚氰胺树脂、不饱和聚酯树脂、环氧树脂、有机硅树脂、聚氨酯及其组合；所述复合材料是由选自玻璃纤维、碳纤维、硼纤维、石墨纤维、碳纳米管、石墨烯、晶须、芳纶纤维、超高分子量聚乙烯纤维、矿物纤维、金属纤维及其组合增强的树脂基复合材料。
进一步地，所述基本周围的第一卡锁构件是由选自以下的方法制备：用于金属的铸造、车削、锻造、焊接、铆接、3D打印、粉末成型工艺，用于塑料的挤出、注射、浇铸、模压、层压、3D打印成型工艺，用于复合材料的手糊、喷射、纤维缠绕成、模压、拉挤、RTM、热压罐、隔膜、迁移、反应注射、软膜膨胀 、冲压成型工艺。
进一步地，所述第一卡锁构件的外侧面向外超出所述面板的外侧面。进一步地，所述面板的外侧面向内倾斜1-45度，优选2-30度、更优选3-15度，例如4-10度、约5度、6度、7度、8度、9度。进一步地，所述面板的外侧面所在的斜面向下延伸穿过所述面板与所述第一卡锁构件之间的胶接层。进一步地，所述第一卡锁构件的上表面设有胶接槽。
在另一个方面，本发明提供一种由根据上述任一项的所述镶嵌式复合地板块通过拼装形成的地板，其中相邻的镶嵌式复合地板块的第一卡锁构件相互配合形成第一卡锁机构。
进一步地，相邻的所述镶嵌式复合地板块各自的面板之间互不碰触并填有勾缝胶。
在再另一个方面，本发明提供一种用于制备根据上述任一项的所述镶嵌式复合地板块的中间件，包括所述第一卡锁构件和自所述第一卡锁构件的上部外缘向外延伸形成的伸出部，所述伸出部的外缘向上延伸形成挡板，所述挡板的内侧面向外倾斜1-45度，优选2-30度、更优选3-15度，例如4-10度、约5度、6度、7度、8度、9度。
进一步地，所述伸出部的上表面与所述第一卡锁构件的上表面平齐或者所述伸出部的上表面向外下方倾斜。
进一步地，所述第一卡锁构件和所述伸出部一体成型或组装成型；优选地，所述组装成型选自焊接、卡扣连接、粘接、插接和销孔连接方式。
在再另一个方面，本发明提供一种制备根据上述任一项的所述镶嵌式复核地板块的方法，包括：
步骤000，提供所述面板、所述基板以及所述第一卡锁构件；
步骤100，在所述基板的外侧面和/或所述中间件中的第一卡锁构件的内侧面上涂布第一胶，将所述基板的外侧面与所述第一卡锁构件的内侧面相互配合并粘接在一起，使得所述凹槽的顶面与所述凸部的上表面的对应位置处形成用于阻止所述凹槽的顶面与所述凸部的上表面相互平移的第二卡锁机构；
步骤200，在所述基板的上表面和所述第一卡锁构件的上表面，和/或所述面板 的下表面上涂布第二胶，将所述面板的下表面与所述基板的上表面和所述第一卡锁构件的上表面相互配合并粘接在一起。
进一步地，在步骤100中，在所述凸部的上表面和/或所述凹槽的顶面涂布第一胶，将所述凸部的上表面和/或所述凹槽的顶面粘接在一起。
进一步地，在步骤000中，所述面板由面原板提供，所述第一卡锁构件由如权利要求23-25中任一项的所述中间件提供，其中所述面板原板的尺寸大于等于所述面板的尺寸并小于等于所述中间件的挡板的内侧面限定的空间的尺寸；
在步骤200中，在所述基板的上表面和所述第一卡锁构件的上表面，和/或所述面板原板的下表面上涂布第二胶，将所述面板原板放入所述中间件的挡板的内侧面限定的空间，并且将所述面板原板的下表面与所述基板的上表面和所述第一卡锁构件的上表面相互配合并粘接在一起；
并且所述方法还包括：步骤300，将所述中间件的挡板和所述面板原板中多于所述面板的部分去除。进一步地，在步骤300中，所述去除通过选自以下的方法进行：磨削、铣削、切割、锯除及其组合。进一步地，在步骤100和/或步骤200中施加压力使所述第一卡锁构件或中间件、所述面板或面板原板以及所述基板压紧在一起。进一步地，在步骤100和/或步骤200中对所述第一卡锁构件或中间件、所述面板或面板原板、所述基板以及所述第一胶和/或第二胶加热。
在本发明的描述中，“基本上”并不排除“完全”的意思。如一个成分“基本上不含”Y，也可以是完全不含有Y。如果需要，“基本上”可以从本发明定义中删除。“含有”既包括提到的因素，也允许包括附加的、不确定的因素。“大约”、“左右”与表示各组分浓度系的情况下，是指标准值的+/-5％，+/-4％，+/-3％，+/-2％，+/-1％，+/-0.5％。“和/或”表示由其连接的多个术语可以各自单独地使用，也可以相互任意地组合。
本发明中，一般通过某一范围来阐述实例，只是为了简洁明了的解释，而不是对本发明的限制。描述的范围包括有子范围，也包括在此范围内所有的单独的数值。例如，1～6这个范围，包括子范围如1～3、1～4、1～5、2～4、2～6、3～6等，也包括此范围内单独的数值，如1、2、3、4、5、6。
在本发明的描述中，需要理解的是，术语“纵向”、“横向”、“上”、“下”、“前” 、“后”、“左”、“右”、“竖直”、“水平”、“顶”、“底”、“内”、“外”等指示的方位或位置关系为基于附图所示的方位或位置关系，仅是为了便于描述本发明，而不是指示或暗示所指的装置或元件必须具有特定的方位、以特定的方位构造和操作，因此不能理解为对本发明的限制。
本发明的镶嵌式复合地板块利用第二卡锁机构将所述第一卡锁构件与所述基板之间的相对位置锁定，避免了所述凹槽的顶面与所述凸部的上表面之间的相互平移，保证了地板块的尺寸精度，这样不但在制造过程中提高了成品率和生产效率，在使用过程中也能进一步地减小地板块的变形。
此外，本发明的镶嵌式复核地板块在充分保证了天然石材等高硬度地板材料的装修效果的同时，还具有高强度、轻质量、可直接拼接、不需要水泥等辅助材料、安装时不易损坏、安全性高等优点，大大提高了工作效率，节约了生产成本，特别适合手工安装，并可大量节约安装人工费和辅料费等，对自己动手安装的DIY爱好者尤其有利。
发明的有益效果
对附图的简要说明
附图说明
图1为本发明的镶嵌式复合地板块的截面结构示意图；
图2为本发明的镶嵌式复核地板块中框架的结构示意图；
图3为本发明另一实施方式的镶嵌式复合地板块的截面结构示意图；
图4为为本发明另一实施方式的镶嵌式复核地板块中框架的结构示意图；
图5为图1中A部分的放大图；
图6为本发明另一实施方式的镶嵌式复核地板块的外侧面的结构示意图；
图7由图1所示的镶嵌式复合地板块拼装的地板覆层的结构示意图；
图8为制备图1所示的镶嵌式复合地板块的榫舌构件中间件(a)和榫槽构件中间件(b)的结构示意图；
图9为制备图1所示的镶嵌式复合地板块的方法的加工状态示意图；
图10为步骤810-840的加工状态示意图；
图11为步骤850的加工状态示意图；
图12适用于本发明的镶嵌式复核地板块的一些卡锁机构的结构示意图。
图中：1-基板；12-第一卡槽；13-第二卡槽；2-榫舌构件；201-第一斜面；202-第一斜面倾角；203-第一卡条；204-榫舌连接件；21-立面；3-榫槽构件；301-第二斜面；302-第二斜面倾角；303-第二卡条；304-榫槽连接件；230-连接条；4-榫舌；5-榫槽；6-面板；7-面板胶接层；8-基板胶接层；9-第一胶；10-第二胶；11-第一胶接槽；31-第二胶接槽；32-第三胶接槽；34-第一伸出部；35-第二伸出部；36-第一挡板；361-第三斜面；362-第三斜面倾角；37-第二挡板；371-第四斜面；372-第四斜面倾角；61-倒角；62-面板外侧面；63-夹角；64-勾缝胶；65-面板原板；66-分离面。
发明实施例
本发明的实施方式
下面将结合本发明实施例中的附图，对本发明实施例中的技术方案进行清楚、完整地描述，显然，所描述的实施例仅仅是本发明一部分实施例，而不是全部的实施例。基于本发明中的实施例，本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例，都属于本发明保护的范围。
参阅图1，本发明的镶嵌式复合地板块包括面板6、基板1和用于连接相邻的镶嵌式复合地板块的第一卡锁构件(包括榫舌构件2和榫槽构件3)。所述第一卡锁构件的内侧面(包括第一斜面201和第二斜面301)向外倾斜，倾角(第一斜面倾角202和第二斜面倾角302)为1-45度，优选2-30度、更优选3-15度，例如4-10度、约5度、6度、7度、8度、9度。所述第一卡锁构件的内侧面通过基板胶接层8胶接于所述基板1的外侧面，所述面板6覆盖并通过面板胶接层7胶接于所述基板1的上表面和所述第一卡锁构件(包括榫舌构件2和榫槽构件3)的上表面。这样，当所述第一卡锁构件的内侧面胶接于与其相对的所述基板1的外侧面时，在二者之间就形成了由下往上逐渐变大的楔形槽，楔形槽可容纳胶接时多余的胶；相比于未向外倾斜的情形，本发明显著减小了多余的胶对第一卡锁构件内侧面和所述基板1外侧面的压力，提高了地板块的尺寸精度，减少了变形，有利地提高了地板块的生产效率和成品率。此外，所述第一卡锁构件的内侧面向外倾斜，使得第一卡锁构件上缘限定的尺寸大于基板1的尺寸，在地板块生产过程 中更容易将基板1与第一卡锁构件装配在一起，可显著减少基板1错搭在第一卡锁构件上表面上的缺陷。
所述基板1的外侧面的下部向所述基板1内部收缩形成凹槽，所述第一卡锁构件的内侧面的下部向所述基板1延伸形成与所述凹槽配合的凸部，所述凹槽的顶面与所述凸部的上表面的对应位置处设有用于阻止所述凹槽的顶面与所述凸部的上表面相互平移的第二卡锁机构。在一些情况下，所述第二卡锁机构包括位于所述凹槽顶面的向上凹陷的卡槽(包括第一卡槽12和第二卡槽13)和位于所述凸部上表面与所述卡槽对应的位置处的向上凸起且与所述卡槽配合的卡条(包括第一卡条203和第二卡条303)。所述凹槽的顶面胶接于所述凸部的上表面；并且所述卡槽胶接于所述卡条。在一些情况下，所述卡槽和卡条的截面轮廓呈梯形、三角形、矩形、波浪形、弧形等。所述卡槽的深度为2-8mm，例如3-7mm，4-6mm，约5mm等；开口宽度为2-8mm，例如3-7mm，4-6mm，约5mm等。所述卡条的高度为1-5mm，例如2-4mm，约3mm等，底部宽度为1-5mm，例如2-4mm，约3mm等。所述卡条和卡槽相互配合形成了第二卡锁机构，有效阻止了所述凹槽的顶面与所述凸部的上表面相互平移，从而保证了地板块的尺寸精度，不但在制造过程中提高了成品率和生产效率，在使用过程中也能进一步地减小地板块的变形。
此外，所述第一卡锁构件的内侧面上设有第三胶接槽32，所述基板1的外侧面上设有多个第一胶接槽11。这些胶接槽一方面增加了楔形槽的容量，有利于减小多余的胶产生的压力，另一方面也增加了基板胶接层8对第一卡锁构件的内侧面和基本1的外侧面的粘结强度。所述第一卡锁构件的上表面也设有第二胶接槽31，用于容纳胶接面层6的多余的胶，以及增加面板胶接层7对面层6的下表面与第一卡锁构件的上表面的粘结强度。
所述第一卡锁构件包括设置在基板相对的两个外侧面的榫舌构件2和榫槽构件3，所述榫舌构件2包括从外侧面向外延伸的榫舌4，所述榫槽构件3包括从外侧面向内延伸的榫槽5，所述榫舌4的外部轮廓与所述榫槽5的内部轮廓相匹配以使具有所述榫舌构件2的镶嵌式复合地板块与相邻的具有所述榫槽构件3的镶嵌式复合地板块之间形成所述榫舌4伸入所述榫槽5的第一卡锁机构，所述第一卡锁机 构阻止相邻的两个镶嵌式复合地板块在垂直方向上和/或水平方向上的相互移动。
如图2所示，在所述基板1的各个侧面上交替地胶接所述榫舌构件2和所述榫槽构件3；并且所述榫舌构件2和所述榫槽构件3相互连接。所述榫舌构件2和榫槽构件3是由金属(选自铝或铝合金、铜或铜合金、铁或铁合金包括不锈钢等)制成的长条状型材(在另一些实施例中，也可以是由热塑性塑料、热固性塑料、纤维增强复合材料(包括碳纤维、玻璃纤维、金属纤维、矿物纤维、碳纳米管等增强的复合材料)等制成的长条状型材)；榫舌构件2包括榫舌4，榫槽构件3包括榫槽5，两对榫舌构件2和榫槽构件3各自相对且平行地设置使得榫舌构件2的除榫舌4之外的部分与榫槽构件3形成边长200-1600毫米，优选300-400毫米、500-600毫米、700-800毫米、900-1000毫米、1100-1200毫米、1300-1400毫米，的正方形框架，其中榫舌构件2和榫槽构件3的相接处通过焊接(例如高频焊接)、插接、铆接或螺丝结构连接和固定；榫舌4从榫舌构件2的侧面向外延伸，榫槽5从榫槽构件5的侧面向内延伸，榫舌4的外部轮廓与榫槽5的内部轮廓相匹配以便一个框架的榫舌能够伸入另一个框架的榫槽中形成连接两个框架的卡锁机构，所述卡锁机构阻止两个框架在垂直方向上的相互移动从而保证了地板覆层的刚性和平整性；在形成的卡锁机构中，榫舌4的长度小于等于对应的榫槽5的长度(例如，二者的长度差为榫舌4宽度的1-4倍，例如2-3倍；在本实施例中为1.5倍)，这样在框架一侧的榫舌4插入与该榫舌4对应的榫槽5中时，可以将框架放平后，再将另一侧的榫舌4插入与其对应的榫槽5，由此显著地改善了地板块的安装效率和方便性，并且明显减少了地板块在安装过程中的损坏率。榫舌4和榫槽5的朝向框架内部的侧面底部向框架中心延伸形成支撑部，支撑部的底面与框架的底面平齐，支撑部的厚度可根据地板块的尺寸选择，尺寸越大厚度越大，通常厚度为0.8-2毫米，例如0.9-1毫米、1.1-1.2毫米、1.3-1.5毫米、1.6-1.8毫米等；支撑部的宽度可以任意选择，越宽对基板的强化程度越大，但成本也会增加，该宽度通常为2-30毫米，例如4-6毫米、8-12毫米、14-16毫米、18-20毫米、25-30毫米等。
基板1置于所述框架的内部，并且基板1的外部轮廓与所述框架的内部轮廓相匹 配。基板1选自玻镁板(又称：氧化镁板、MGO板等)、混凝土板(可以任选地包括轻质陶粒或发泡水泥砂浆)、热塑性塑料板、热固性层板、蜂窝铝板、粗纸板、刨花板、密度板、木板等中密度较小的那些板材，例如密度小于等于每立方厘米3克、2.5克、2克、1.5克、1克、0.8克、0.6克等的那些板材。在一些实施方式中，基板1可以是由选自上述是各种板材层叠而成的复合基板。在一些情况下，基板1还包括贴附在基板1底面上的软木垫层、橡胶垫层、防水背胶层等中的一个或多个。在以上各种情况中，构成基板1的各层板中的一个或多个之中还铺设有纤维(例如玻璃纤维、碳纤维、矿物纤维、金属纤维、有机高分子材料纤维等)以便进一步增强基板1的强度。基板1的底面与框架的底面平齐，上表面与框架的上表面平齐，并且基板1的总厚度与框架的厚度一致，通常为5-20毫米，例如6-7毫米、7.5-8.5毫米、9-11毫米、12-15毫米等。基板1的底部边缘还设有用于容纳所述框架的支撑部的凹槽，所述凹槽与支撑板的外部轮廓相匹配。在一些情况下，基板1中的至少一层板由水平拼装的多个子板构成，子板之间设有预留缝隙以容纳基板1超出所述框架的形变。
基板1的侧壁与由榫舌构件2和榫槽构件3构成的框架的内壁通过基板胶接层8连接，基板1的底部边缘的凹槽内壁通过基板胶接层8与所述框架的支撑部的上表面连接。在一些情况下，在所述框架的内壁上设有胶接槽32，在所述框架的支撑部的上表面上设有胶接槽31，并且在基板1的侧壁上设有胶接槽12，在基板1的底部边缘的凹槽内壁上设有胶接槽11，胶接层8延伸进入这些胶接槽中，由此显著地增强基板1与框架之间的连接强度。
面板6通过面板胶接层7连接在基板1和由榫舌构件2和榫槽构件3构成的框架的上表面。面板6为高硬度薄板，特别是高硬度脆性薄板，选自由石材(包括天然石材和人造石材，优选天然石材)、陶瓷、玻璃或金属(例如不锈钢等)制成的薄板。面板6的厚度可以是任意合适的厚度，例如1-10毫米、1.2-8毫米、1.5-5毫米、2-4毫米、约3毫米等。在一些情况下，所述框架的上表面设有胶接槽33，由此显著增强了面板6与基板1和所述框架之间的连接强度。
在一些情况，上述各个胶接槽中的一个或多个的口部宽度略小于底部宽度，例如口部宽度为底部宽度的60-99％，70-95％，80-90％等；这样可以进一步增强基 板1与框架之间的连接强度。在一些情况下，上述各个胶接槽中的一个或多个的口部宽度为0.5-5毫米，例如0.6-4毫米、0.8-3毫米、1-2毫米等，胶接槽的深度为0.2-2毫米、例如0.25-1.5毫米、0.3-1毫米、0.35-0.8毫米、0.4-0.6毫米、约0.5毫米等。在一些情况下，在上述各处可以根据需要设置任意多个胶接槽，例如1-5个胶接槽。
如图3所示，在所述基板1的相对和/或相邻的第一侧面和第二侧面上分别胶接所述榫舌构件2和所述榫槽构件3，所述榫舌构件2的底部与所述榫槽构件3的底部之间通过连接条230相互固定连接。
如图4所示，所述第一卡锁构件以连续或断续的方式胶接于矩形基板1的外侧面，其中在所述基板1的一个边的外侧面的榫舌结构2包括多段，各段之间通过榫舌连接件204连接；在所述基板1的另一个边的外侧面的榫槽结构3包括多段，各段之间通过是榫槽连接件304连接；在所述基板1的一个角部的相邻两边的两个第一卡锁构件各自的一端相互固定连接以便将该角部包围，各自的另一端通过连接条230相互固定连接。
如图5和图6所示，所述第一卡锁构件的外侧面所在的立面21向外超出所述面板的外侧面62。
如图5所示，所述面板的外侧面向内倾斜1-45度，优选2-30度、更优选3-15度，例如4-10度、约5度、6度、7度、8度、9度。例如，所述面板的外侧面所在的斜面向下延伸穿过所述面板与所述第一卡锁构件之间的胶接层。面板6的四个边部均具有自下而上向面板6中心倾斜的面板外侧面62，所述斜面与所述框架的侧壁所在的立面21之间的夹角63为3-45度，例如4-40度、5-30度、10-25度、15-20度等，并且面板外侧面62向下延伸穿入或穿过面板胶接层6后与所述立面21或者所述侧壁本身相交，但不与榫舌4或榫槽5相交。例如，当面板外侧面62向下延伸穿入面板胶接层6后就与所述框架的侧壁所在立面21相交；当面板外侧面62向下延伸穿过面板胶接层6后继续延伸穿过所述框架，就会与所述框架的侧壁相交；尤其是当面板外侧面62向下延伸穿过面板胶接层6后，还可以恰好与所述框架的侧壁的上部外缘相交。这样设置的面板外侧面62可以显著地避免地板块拼装时面板6之间相互碰撞而导致的损坏，并且在拼装过程中允许一个地板块以一定的 倾斜角度与另一个地板块相互拼接，由此极大地减少了地板块在安装时的损坏，并且显著地提高了安装效率，减轻了安装劳动的强度。
如图6所示，面板外侧面62也可向内收缩并与立面21基本保持平行，由此避免地板块拼装时面板6之间相互碰撞而导致的损坏。在一些情况下，面板外侧面62和面板胶接层7的上部共同向内收缩，这有利于通过去除部分面板外侧面62以便使得面板外侧面62位于立面21的内侧。
如图5和图6所示，面板6的上表面与面板外侧面62相交处的棱部具有倒角61，倒角61的半径为0.5-20毫米，优选1-15毫米，例如0.6-4毫米、0.7-3毫米、0.8-2毫米、约1毫米等。设置倒角可以显著减少安装过程中棱部的损坏，并有效避免锋锐的棱部割伤安装人员。
如图7所示，由本发明的镶嵌式复合地板块通过拼装形成的地板中，相邻的镶嵌式复合地板块的第一卡锁构件相互配合形成第一卡锁机构，并且相邻的所述镶嵌式复合地板块各自的面板之间互不碰触并填有勾缝胶64。例如，其中一个地板块的榫舌4插入了另一个地板块的榫槽5，而两个地板块各自的面板6之间并没有碰触。拼装后，由各自的斜面63形成的缝隙中加入了具有一定弹性且能够防水的勾缝胶64，例如环氧胶等，由此在防止渗水的同时还允许面板6在膨胀时相互之间不发生碰撞，在收缩时仍能保持对该缝隙的密封。
在本发明中，上述各种胶接层和勾缝胶所用的胶可以是任意的现有技术中已知的那些能够适用的胶，例如环氧胶、聚氨酯胶等。
本发明的镶嵌式复核地板块在充分保证了天然石材等高硬度地板材料的装修效果的同时，还具有高强度、轻质量、可直接拼接、不需要水泥等辅助材料、安装时不易损坏、安全性高等优点，特别适合手工安装，并可大量节约安装人工费和辅料费等，对自己动手安装的DIY爱好者由其有利。
图8给出了制备本发明的镶嵌式复合地板块的榫舌构件中间件(a)和榫槽构件中间件(b)的结构示意图，其中榫舌构件中间件包括榫舌构件2，自榫舌构件2的上部外缘基本水平地向外延伸形成伸出部34，以及自伸出部35的外端基本竖直地向上延伸形成第一挡板36；榫槽构件中间件包括榫槽构件3，自榫槽构件3的上部外缘基本水平地向外延伸形成的伸出部35，以及自伸出部35的外端基本 竖直地向上延伸形成的第二挡板37。所述第一挡板36的内侧面向外倾斜成为第三斜面361，所述第二挡板37的内侧面向外倾斜成为第四斜面371，第三斜面361的第三斜面倾角362以及第四斜面371的第四斜面倾角372均为1-45度，优选2-30度、更优选3-15度，例如4-10度、约5度、6度、7度、8度、9度。所述第一伸出部34和第二伸出部35的上表面与所述第一卡锁构件的上表面平齐或者向外下方倾斜。所述第一卡锁构件中的榫舌结构2、所述第一伸出部34和第一挡板36一体成型或组装成型；所述第一卡锁构件中的榫槽结构3、所述第二伸出部35和第二挡板37一体成型或组装成型。所述组装成型选自焊接、卡扣连接、粘接、插接和销孔连接方式。
图9为制备图1所示的镶嵌式复合地板块的方法的加工状态示意图，相应的制备根方法包括：
步骤000，提供所述面板6、所述基板1以及所述第一卡锁构件(榫舌构件2和榫槽构件3)；
步骤100，在所述基板1的外侧面和/或所述中间件中的第一卡锁构件的内侧面上涂布第一胶9，将所述基板1的外侧面与所述第一卡锁构件的内侧面相互配合并粘接在一起，使得所述凹槽的顶面与所述凸部的上表面的对应位置处形成用于阻止所述凹槽的顶面与所述凸部的上表面相互平移的第二卡锁机构；
步骤200，在所述基板1的上表面和所述第一卡锁构件的上表面，和/或所述面板6的下表面上涂布第二胶10，将所述面板6的下表面与所述基板1的上表面和所述第一卡锁构件的上表面相互配合并粘接在一起。
当所述第一卡锁构件的内侧面胶接于与其相对的所述基板1的外侧面时，在二者之间就形成了由下往上逐渐变大的楔形槽，楔形槽可容纳胶接时多余的胶；相比于未向外倾斜的情形，本发明显著减小了多余的胶对第一卡锁构件内侧面和所述基板1外侧面的压力，提高了地板块的尺寸精度，减少了变形，有利地提高了地板块的生产效率和成品率。此外，所述第一卡锁构件的内侧面向外倾斜，使得第一卡锁构件上缘限定的尺寸大于基板1的尺寸，在地板块生产过程中更容易将基板1与第一卡锁构件装配在一起，可显著减少基板1错搭在第一卡锁构件上表面上的缺陷。
所述卡条和卡槽相互配合形成了第二卡锁机构，有效阻止了所述凹槽的顶面与所述凸部的上表面相互平移，从而保证了地板块的尺寸精度，不但在制造过程中提高了成品率和生产效率，在使用过程中也能进一步地减小地板块的变形。
此外，所述第一卡锁构件的内侧面上设有第三胶接槽32，所述基板1的外侧面上设有多个第一胶接槽11。这些胶接槽一方面增加了楔形槽的容量，有利于减小多余的胶产生的压力，另一方面也增加了基板胶接层8对第一卡锁构件的内侧面和基本1的外侧面的粘结强度。所述第一卡锁构件的上表面也设有第二胶接槽31，用于容纳胶接面层6的多余的胶，以及增加面板胶接层7对面层6的下表面与第一卡锁构件的上表面的粘结强度。
在步骤100中，在所述凸部的上表面和/或所述凹槽的顶面涂布第一胶9，将所述凸部的上表面和/或所述凹槽的顶面粘接在一起。
在一些情况下，在步骤000中，所述面板6由面原板65提供，所述第一卡锁构件由所述中间件提供，其中所述面板原板65的尺寸大于等于所述面板6的尺寸并小于等于所述中间件的第一挡板36和第二挡板37的内侧面限定的空间的尺寸；
在步骤200中，在所述基板1的上表面和所述第一卡锁构件的上表面，和/或所述面板原板65的下表面上涂布第二胶10，将所述面板原板65放入所述中间件的第一挡板36和第二挡板37的内侧面限定的空间，并且将所述面板原板65的下表面与所述基板1的上表面和所述第一卡锁构件的上表面相互配合并粘接在一起；。
并且所述方法还包括：
步骤300，将所述中间件的第一挡板36和第二挡板37以及第一伸出部34、第二伸出部35和所述面板原板65中多于所述面板6的部分去除，所述去除通过选自以下的方法进行：磨削、铣削、切割、锯除及其组合。
通过将中间件的第一伸出部34和第二伸出部35与所述面板原板65同时去除，可以保证面板6的外侧面与第一卡锁构件的外侧面保持高度一致，由此提高了地板块的尺寸精度和一致性，并且简化了工艺。此外，第一挡板36的第三斜面361和第二挡板37的第四斜面371使得第一挡板36和第二挡板37限定了从上往下逐渐缩小的空间，有利于将面板原板65方便地放置到空间底部的基板1的上表面，避免 了与所述空间尺寸接近的面板原板65容易搁置在第一挡板36和第二挡板37上方的问题；并且有利于将剩余的胶从面板原板65的外侧面与第三斜面361和第四斜面271分别形成的楔形槽中以更低的压力排出，避免该压力引起的第一卡锁构件变形的问题，由此更进一步地提高了地板块的尺寸精度和一致性。
此外，在步骤100和/或步骤200中施加压力使所述第一卡锁构件或中间件、所述面板或面板原板以及所述基板压紧在一起，以及在步骤100和/或步骤200中对所述第一卡锁构件或中间件、所述面板或面板原板、所述基板以及所述第一胶和/或第二胶加热。
在另一些实施方式中，本发明镶嵌式复核地板块的制备方法包括：
步骤500，提供如图8所示的榫舌构件中间件和榫槽构件中间件，基板1和面板原板65，所述面板原板65的尺寸略大于面板6的尺寸；
步骤600，根据所需地板块的尺寸用步骤500的两根所述榫舌构件中间件和两根所述榫槽构件中间件构成包括如图2所示框架的中间框架；
步骤700，在基板1的侧壁和底部边缘凹槽内壁上和/或步骤600的中间框架内部侧壁和底部上表面上涂第一胶9，然后将基板1放入所述中间框架内，保持基板1的底面与中间框架的底面平齐直至所述第一胶9固化形成基板胶接层8；
步骤800，在进行步骤700后的基板1的上表面和所述中间框架的上表面涂第二胶10，然后将面板原板65安放在第二胶10上和挡板61所围出的空间内，直至第二胶10固化形成面板胶接层7，得到地板块中间体；
步骤900，在地板块中间体中，沿立面21和面板外侧面62将伸出部34-35、挡板36-37以及面板原板65上多余的部分除去，得到所述镶嵌式复核地板块。
如图10和图11所示，在一些情况下，当所述面板原板65的厚度为面板6厚度两倍以上时，所述方法在步骤800和步骤900之间还包括：
步骤810，提供第二套如图8所示的两根榫舌构件中间件和两根榫槽构件中间件，以及基板1；
步骤820，根据所需地板块的尺寸用步骤810的两根所述榫舌构件中间件和两根所述榫槽构件中间件构成包括如图2所示框架的中间框架；
步骤830，在步骤810的基板1的侧壁和底部边缘凹槽内壁上和/或步骤820的中 间框架内部侧壁和底部上表面上涂第一胶9，然后将基板1放入所述中间框架内，保持基板1的底面与中间框架的底面平齐直至所述第一胶9固化形成基板胶接层8；
步骤840，在步骤830的基板1的上表面和所述中间框架的上表面涂第二胶10，然后将步骤800的面板原板65的另一面安放在第二脚10上和挡板61所围出的空间内，直至第二胶10固化形成面板胶接层7；
步骤850，将步骤840后的面板原板65沿水平的分离面66从中间分离，得到两个地板块中间体。
在上述方法中，第一胶9和第二胶10均选自现有技术中任意合适的胶，例如环氧胶和聚氨酯胶等，其固化均在供应商提供的条件或公知的条件下进行。
在另一些实施方式中，所述卡锁机构中的榫舌构件中间件和榫槽构件中间件的结构可以选自图12中所示的成对结构A1-A2、B1-B2、C1-C2、D1-D2、E1-E2、F1-F2、G1-G2中的任意一对，以便形成适用于各种不同的需求的卡锁机构，其中虚线示出了将各对中间件中包括的伸出部34-35和挡板36-37与榫舌构件和榫槽构件分离的位置(相当于立面21)；另外，榫舌构件和榫槽构件的与基板和面板胶接的壁面上都设有胶接槽。
对于本领域技术人员而言，显然本发明不限于上述示范性实施例的细节，而且在不背离本发明的精神或基本特征的情况下，能够以其他的具体形式实现本发明。因此，无论从哪一点来看，均应将实施例看作是示范性的，而且是非限制性的，本发明的范围由所附权利要求而不是上述说明限定，因此旨在将落在权利要求的等同要件的含义和范围内的所有变化囊括在本发明内。不应将权利要求中的任何附图标记视为限制所涉及的权利要求。
此外，应当理解，虽然本说明书按照实施方式加以描述，但并非每个实施方式仅包含一个独立的技术方案，说明书的这种叙述方式仅仅是为清楚起见，本领域技术人员应当将说明书作为一个整体，各实施例中的技术方案也可以经适当组合，形成本领域技术人员可以理解的其他实施方式。

Claims (31)

  1. 一种镶嵌式复合地板块，包括面板、基板和用于连接相邻的镶嵌式复合地板块的第一卡锁构件，所述第一卡锁构件的内侧面胶接于所述基板的外侧面，所述面板覆盖并胶接于所述基板的上表面和所述第一卡锁构件的上表面，所述基板的外侧面的下部向所述基板内部收缩形成凹槽，所述第一卡锁构件的内侧面的下部向所述基板延伸形成与所述凹槽配合的凸部，所述凹槽的顶面与所述凸部的上表面的对应位置处设有用于阻止所述凹槽的顶面与所述凸部的上表面相互平移的第二卡锁机构。
  2. 根据权利要求1的所述镶嵌式复合地板块，其中所述第二卡锁机构包括位于所述凹槽顶面的向上凹陷的卡槽和位于所述凸部上表面与所述卡槽对应的位置处的向上凸起且与所述卡槽配合的卡条。
  3. 根据权利要求1的所述镶嵌式复合地板块，其中所述第二卡锁机构包括位于所述凹槽顶面的向下凸起的卡条和位于所述凸部上表面与所述卡条对应的位置处的向下凹陷且与所述卡条配合的卡槽。
  4. 根据权利要求1的所述镶嵌式复合地板块，其中所述第二卡锁机构包括位于所述凹槽顶面的向上凹陷的第一卡槽、位于所述凸部上表面与所述第一卡槽对应的位置处的向下凹陷的第二卡槽，以及伸入所述第一卡槽和第二卡槽并与其配合的卡条。
  5. 根据前述权利要求中任一项的所述镶嵌式复合地板块，其中所述凹槽的顶面胶接于所述凸部的上表面；并且，任选地，所述卡槽胶接于所述卡条。
  6. 根据前述权利要求中任一项的所述镶嵌式复合地板块，其中所述第一卡锁构件的内侧面向外倾斜1-45度，优选2-30度、更优选3-15度，例如4-10度、约5度、6度、7度、8度、9度。
  7. 根据前述权利要求中任一项的所述镶嵌式复合地板块，其中所述第一卡锁构件的内侧面和/或所述基板的外侧面上设有一个或更多个胶接槽。
  8. 根据前述权利要求中任一项的所述镶嵌式复合地板块，其中所述第一卡锁构件选自榫舌构件和榫槽构件，所述榫舌构件包括从外侧面向外延伸的榫舌，所述榫槽构件包括从外侧面向内延伸的榫槽，所述榫舌的外部轮廓与所述榫槽的内部轮廓相匹配以使具有所述榫舌构件的镶嵌式复合地板块与相邻的具有所述榫槽构件的镶嵌式复合地板块之间形成所述榫舌伸入所述榫槽的第一卡锁机构，所述第一卡锁机构阻止相邻的两个镶嵌式复合地板块在垂直方向上和/或水平方向上的相互移动。
  9. 根据权利要求8的所述镶嵌式复合地板块，其中在所述基板的相对和/或相邻的第一侧面和第二侧面上分别胶接所述榫舌构件和所述榫槽构件，所述榫舌构件的底部与所述榫槽构件的底部之间通过连接条相互固定连接。
  10. 根据权利要求8或9的所述镶嵌式复合地板块，其中在所述基板的各个侧面上交替地胶接所述榫舌构件和所述榫槽构件；并且所述榫舌构件和所述榫槽构件相互连接。
  11. 根据前述权利要求中任一项的所述镶嵌式复合地板块，其中所述第一卡锁构件以连续或断续的方式胶接于所述基板的外侧面。。
  12. 根据权利要求11的所述镶嵌式复合地板块，其中所述基板是凸多边形，所述第一卡锁构件以连续的方式包围所述凸多边形的各个顶角，其中所述凸多边形选自三、四、五、六、七、八边形，优选自正三、四、五、六、七、八边形，更优选自矩形，更优选自正方形、正六边形。
  13. 根据前述权利要求中任一项的所述镶嵌式复合地板块，其中所述面板为硬质薄板，选自由天然石材、陶瓷、玻璃、石英、人造石材或金属制成的薄板。
  14. 根据前述权利要求中任一项的所述镶嵌式复合地板块，其中所述基板选自玻镁板、混凝土板、热塑性塑料板、热固性层板、蜂窝铝板、粗纸板、刨花板、密度板、木板、木塑板及其相互组合形 成的板。
  15. 根据前述权利要求中任一项的所述镶嵌式复合地板块，其中所述第一卡锁构件是由选自铝或铝合金、铜或铜合金、铁或铁合金、钛或钛合金、热塑性塑料、热固性塑料、复合材料制成的型材，其中所述热塑性塑料选自ABS树脂、聚乙烯、聚丙烯、聚砜树脂、聚碳酸酯、聚苯醚、聚苯硫醚、聚丙烯酸树脂、聚氯乙烯树脂、氟树脂、聚芳醚酮、聚苯酯、聚甲醛、聚酰胺及其组合；所述热固性塑料选自酚醛树脂、脲醛树脂、三聚氰胺树脂、不饱和聚酯树脂、环氧树脂、有机硅树脂、聚氨酯及其组合；所述复合材料是由选自玻璃纤维、碳纤维、硼纤维、石墨纤维、碳纳米管、石墨烯、晶须、芳纶纤维、超高分子量聚乙烯纤维、矿物纤维、金属纤维及其组合增强的树脂基复合材料。
  16. 根据权利要求15的所述镶嵌式复合地板块，其中所述基本周围的第一卡锁构件是由选自以下的方法制备：用于金属的铸造、车削、锻造、焊接、铆接、3D打印、粉末成型工艺，用于塑料的挤出、注射、浇铸、模压、层压、3D打印成型工艺，用于复合材料的手糊、喷射、纤维缠绕成、模压、拉挤、RTM、热压罐、隔膜、迁移、反应注射、软膜膨胀、冲压成型工艺。
  17. 根据前述权利要求中任一项的所述镶嵌式复合地板块，其中所述第一卡锁构件的外侧面向外超出所述面板的外侧面。
  18. 根据权利要求17的所述镶嵌式复合地板块，其中所述面板的外侧面向内倾斜1-45度，优选2-30度、更优选3-15度，例如4-10度、约5度、6度、7度、8度、9度。
  19. 根据权利要求18的所述镶嵌式复合地板块，其中所述面板的外侧面所在的斜面向下延伸穿过所述面板与所述第一卡锁构件之间的胶接层。
  20. 根据前述权利要求中任一项的所述镶嵌式复合地板块，其中所述第一卡锁构件的上表面设有胶接槽。
  21. 一种由根据权利要求1-20中任一项的所述镶嵌式复合地板块通过拼装形成的地板，其中相邻的镶嵌式复合地板块的第一卡锁构件相互配合形成第一卡锁机构。
  22. 根据权利要求21的所述地板，其中相邻的所述镶嵌式复合地板块各自的面板之间互不碰触并填有勾缝胶。
  23. 一种用于制备根据权利要求1-20中任一项的所述镶嵌式复合地板块的中间件，包括所述第一卡锁构件和自所述第一卡锁构件的上部外缘向外延伸形成的伸出部，所述伸出部的外缘向上延伸形成挡板，所述挡板的内侧面向外倾斜1-45度，优选2-30度、更优选3-15度，例如4-10度、约5度、6度、7度、8度、9度。
  24. 根据权利要求23的所述中间件，其中所述伸出部的上表面与所述第一卡锁构件的上表面平齐或者所述伸出部的上表面向外下方倾斜。
  25. 根据权利要求23的所述中间件，其中所述第一卡锁构件和所述伸出部一体成型或组装成型；优选地，所述组装成型选自焊接、卡扣连接、粘接、插接和销孔连接方式。
  26. 一种制备根据权利要求1-20中任一项的所述镶嵌式复核地板块的方法，包括：
    步骤000，提供所述面板、所述基板以及所述第一卡锁构件；
    步骤100，在所述基板的外侧面和/或所述中间件中的第一卡锁构件的内侧面上涂布第一胶，将所述基板的外侧面与所述第一卡锁构件的内侧面相互配合并粘接在一起，使得所述凹槽的顶面与所述凸部的上表面的对应位置处形成用于阻止所述凹槽的顶面与所述凸部的上表面相互平移的第二卡锁机构；
    步骤200，在所述基板的上表面和所述第一卡锁构件的上表面，和/或所述面板的下表面上涂布第二胶，将所述面板的下表面与所述基板的上表面和所述第一卡锁构件的上表面相互配合并粘接在一起。
  27. 根据权利要求26的所述方法，其中在步骤100中，在所述凸部的上表面和/或所述凹槽的顶面涂布第一胶，将所述凸部的上表面和/或所述凹槽的顶面粘接在一起。
  28. 根据权利要求26或27的所述方法，其中，
    在步骤000中，所述面板由面原板提供，所述第一卡锁构件由如权利要求23-25中任一项的所述中间件提供，其中所述面板原板的尺寸大于等于所述面板的尺寸并小于等于所述中间件的挡板的内侧面限定的空间的尺寸；
    在步骤200中，在所述基板的上表面和所述第一卡锁构件的上表面，和/或所述面板原板的下表面上涂布第二胶，将所述面板原板放入所述中间件的挡板的内侧面限定的空间，并且将所述面板原板的下表面与所述基板的上表面和所述第一卡锁构件的上表面相互配合并粘接在一起；
    并且所述方法还包括：
    步骤300，将所述中间件的挡板和所述面板原板中多于所述面板的部分去除。
  29. 根据1权利要求28的所述方法，其中在步骤300中，所述去除通过选自以下的方法进行：磨削、铣削、切割、锯除及其组合。
  30. 根据权利要求26-29中任一项的所述方法，其中在步骤100和/或步骤200中施加压力使所述第一卡锁构件或中间件、所述面板或面板原板以及所述基板压紧在一起。
  31. 根据权利要求26-30中任一项的所述方法，其中在步骤100和/或步骤200中对所述第一卡锁构件或中间件、所述面板或面板原板、所述基板以及所述第一胶和/或第二胶加热。
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