WO2019196122A1 - 一种复合板材及其制造方法 - Google Patents

一种复合板材及其制造方法 Download PDF

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Publication number
WO2019196122A1
WO2019196122A1 PCT/CN2018/083119 CN2018083119W WO2019196122A1 WO 2019196122 A1 WO2019196122 A1 WO 2019196122A1 CN 2018083119 W CN2018083119 W CN 2018083119W WO 2019196122 A1 WO2019196122 A1 WO 2019196122A1
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WO
WIPO (PCT)
Prior art keywords
layer
substrate layer
composite
composite sheet
wear
Prior art date
Application number
PCT/CN2018/083119
Other languages
English (en)
French (fr)
Inventor
王彪
胡文跃
派恩·杰森
杭承
Original Assignee
王彪
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by 王彪 filed Critical 王彪
Priority to PCT/CN2018/083119 priority Critical patent/WO2019196122A1/zh
Priority to US16/307,306 priority patent/US20190368204A1/en
Publication of WO2019196122A1 publication Critical patent/WO2019196122A1/zh

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Definitions

  • the invention relates to the field of building consumables, in particular to a composite board and a manufacturing method thereof.
  • boards laid on the floor or wall are usually waterproof, moisture-proof, low-cost, and not easily deformed.
  • the market uses fiberboard or particle board laminate flooring, or tile, stone and other hard materials, according to different needs of users, choose wood board, plastic sheet, hard board, etc. laid on the floor or wall .
  • the material itself has the characteristics of beautifying utensils, easy to be washed, and not eroded by dust, but the hardness is higher, the toughness is poor, and the external deformation variables can be withstood. less. If the tile or stone receives external stress, it will crack or break. Therefore, when installing tiles, stone on the wall or on the ground, it is usually laid by hand and bonded by adhesive, cement, etc. On the body of ceramic tiles and stone, there is no additional structure for fixing to each other after cutting or cutting.
  • the object of the present invention is to provide a composite board and a manufacturing method thereof, which can reduce the amount of binder used and harmful substances in the process of paving tiles and the like, and can be installed in green. Effect. At the same time, each part is used for its own, bringing a new impact on the product line for the home improvement industry.
  • the invention discloses a composite board comprising:
  • the substrate layer further includes a fixing member disposed on both sides of the substrate layer, and when at least two composite sheets are joined, the fixing members are coupled to each other to relatively fix the composite sheet.
  • the substrate layer comprises a composite of stone powder and plastic
  • the wear layer comprises a hard material.
  • the composite is a WPC wood plastic floor or a SPC stone plastic floor;
  • the hard material is a tile or stone.
  • the substrate layer is bonded to the wear layer and then formed at a high temperature or a cold press.
  • the composite sheet further comprises:
  • the first bonding layer is bonded between the substrate layer and the wear layer.
  • the composite sheet further comprises:
  • the substrate layer is disposed on the other side of the substrate layer relative to the wear layer and is relatively fixed to the substrate layer.
  • the composite sheet further comprises:
  • the second bonding layer is bonded between the substrate layer and the substrate layer.
  • the fixing element is a locking element
  • the locking component includes a mounting groove and a mounting rib disposed on two sides of the base material layer, and the mounting rib is matched with the mounting groove to fix a plurality of the base material layers.
  • the mounting rib further includes a limiting groove, and a surface of the mounting groove protrudes to form a finite rib;
  • the limiting ribs are mated with the limiting slots to limit axial and radial displacement between the plurality of substrate layers.
  • the substrate layer comprises a mounting surface facing the wear layer
  • a pair of opposite edges of the wear layer are attached to opposite edges of the mounting surface, and another pair of opposite edges are disposed within a projecting range of the mounting surface.
  • the surface of the wear layer is pre-opened with a decorative seam
  • the decorative slit is parallel to the width direction of the wear layer.
  • the invention also discloses a method for manufacturing a composite board, comprising the following steps:
  • Step S100 taking a substrate layer as a core of the composite sheet
  • Step S200 opening fixing elements on both sides of the substrate layer for relatively fixing the composite plate
  • Step S300 laying a wear layer on the substrate layer and fixing on the substrate layer.
  • the hardness of the wear layer and the toughness of the substrate layer can be simultaneously utilized to form a nearly perfect composite sheet which can be applied to any occasion;
  • the waterproof, moisture-proof, anti-deformation and the like characteristics of the substrate layer itself enable the composite sheet of the present invention to not undergo excessive deformation upon receiving an abnormal change in temperature, thereby affecting the original structure of the composite sheet.
  • FIG. 1 is a schematic structural view of a composite board in accordance with a preferred embodiment of the present invention.
  • FIG. 2 is a schematic structural view of a composite board having a first bonding layer in accordance with a preferred embodiment of the present invention
  • FIG. 3 is a schematic structural view of a composite board having a second bonding layer in accordance with a preferred embodiment of the present invention
  • FIG. 4 is a schematic structural view of a composite board having both a first bonding layer and a second bonding layer in accordance with a preferred embodiment of the present invention
  • Figure 5 is a schematic view showing the structure of a locking member on a substrate layer of a composite board in accordance with a preferred embodiment of the present invention
  • FIG. 6 is a schematic structural view of a locking component on a substrate layer of a composite board in accordance with another preferred embodiment of the present invention.
  • FIG. 7 is a schematic structural view of a locking component on a substrate layer of a composite board in accordance with still another preferred embodiment of the present invention.
  • Figure 8 is a schematic view showing the structure of a locking member on a substrate layer of a composite board in accordance with still another preferred embodiment of the present invention.
  • FIG. 9 is a schematic structural view of a locking component on a substrate layer of a composite board in accordance with still another preferred embodiment of the present invention.
  • Figure 10 is a schematic view showing the structure of a locking member on a substrate layer of a composite board in accordance with still another preferred embodiment of the present invention.
  • Figure 11 is a schematic view showing the structure of a composite board having a decorative seam in accordance with a preferred embodiment of the present invention.
  • Figure 12 is a schematic view showing the structure of a composite panel having decorative slits in accordance with another preferred embodiment of the present invention.
  • first, second, third, etc. may be used in the present disclosure to describe various information, such information should not be limited to these terms. These terms are only used to distinguish the same type of information from each other.
  • first information may also be referred to as second information without departing from the scope of the present disclosure.
  • second information may also be referred to as first information.
  • word “if” as used herein may be interpreted as "when” or "when” or "in response to determination"
  • the composite panel 100 includes two main substrates, a substrate layer 110 and a wear layer 120, respectively.
  • the substrate layer 110 serves as a core of the composite sheet 100, is disposed in the middle portion of the composite sheet 100, or is bonded as a bottom layer to a floor or wall surface on which the composite sheet 100 needs to be laid.
  • the wear layer 120 is coated on the substrate layer 110 and fixed on the substrate layer 110 by an adhesive or other processing method without using an adhesive, so that the composite sheet 100 of the present invention is at least composed of the substrate layer 110 and The wear layer 120 is composed of.
  • the wear-resistant layer 120 faces the exterior of the floor or wall surface on which the composite floor is laid, and directly contacts the furniture, the user, etc., and the surface thereof is optionally covered with a non-slip film, a wear-resistant film, a matt film, and the like. Used to enhance wear resistance or decorative effects.
  • the substrate layer 110 comprises a composite of stone powder and plastic, or a common wood floor, etc., and may also be a pressed-chip material including bamboo chips, wood chips, cork chips or a mixture, or may be High density polyethylene material excluding crumb material, either native PVC, recycled PVC, or a combination of the two. Regardless of which of the above ingredients is used, the composite material is press-formed into the composite sheet 100 after the materials used are mixed.
  • the wear layer 120 comprises a hard material or consists essentially of a hard material mixed with other additive materials.
  • the substrate layer 110 comprises a composite of WPC wood-plastic flooring or SPC stone-plastic flooring.
  • the main components of SPC stone plastic flooring include polyvinyl chloride, calcium carbonate, stabilizer, yellow foam (ADC foaming agent), white foam (NC foaming agent), and other chemical additives, such as lubricants, antibacterial agents.
  • ADC foaming agent yellow foam
  • NC foaming agent white foam
  • lubricants antibacterial agents.
  • the PVC substrate is extruded through an extruder combined with a T-die, and the PVC wear layer, PVC color film and PVC substrate are respectively heated and bonded by a three-roll or four-roll calender. After embossing, the process is simple, the bonding is done by heat, and no glue is needed. More specifically, the preparation can be completed by the following steps:
  • the hot mixing temperature can be 125 ° C, which is used to make the various materials mix evenly, remove the moisture in the material, and then mix into the cold mix after hot mixing to cool the material.
  • the cold mixing temperature can be 55 ° C, and finally the homogeneously mixed material is cooled.
  • the material is added to a twin-screw extruder, heated and extruded, and then extruded into a sheet die, and the formed sheet is subjected to a four-roll calender, the substrate is fixed in thickness, and the multi-step paste film is attached.
  • the wear layer 120 (which may be omitted in the present invention) is post-cooled and finally cut into shape.
  • the material after cutting and forming is subjected to surface UV and tempering, wherein the temperature of the hot water used for tempering is between 80 and 120 ° C, and the temperature of cold water is about 10 ° C.
  • the material is cut and slotted, trimmed, chamfered, and packaged and transported after the inspection is completed.
  • SPC stone-plastic flooring are environmentally friendly and do not contain harmful substances such as heavy metals, phthalates, methanol, etc., and are 100% formaldehyde-free. Structurally, SPC stone plastic floor thickness is only 4-5.5 mm, non-toxic and tasteless, not afraid of water, not afraid of fire, not afraid of tide; scratch resistance, resource use, anti-slip performance, SPC stone plastic floor is better than laminate flooring. In addition to the above basic properties, SPC stone plastic flooring also has shrinkage: ⁇ 1 ⁇ (after tempering), ⁇ 2.5 ⁇ (before tempering), and its floor density is about 1.9 ⁇ 2 tons / cubic meter To make its physical indicators stable and reliable, and the chemical indicators meet international and national standards.
  • WPC wood-plastic floor
  • WPC is the abbreviation of Wood Plastic Composition, which is mainly composed of wood (wood cellulose, plant cellulose) and thermoplastic polymer materials (plastics) and processing aids. The material is made by mixing and then being extruded by the mold equipment, and has the properties and characteristics of wood and plastic.
  • WPS wood plastic floor also includes: foaming regulator (methyl methacrylate-butyl acrylate-styrene polymer), calcium zinc stabilizer (zinc stearate, calcium stearate), Internal lubrication 60, PE wax (Fischer-Tropsch wax), yellow foam (ADC foaming agent), white foaming (NC foaming agent), high-temperature lubricating (oxidized polyethylene wax), any one or more.
  • foaming regulator methyl methacrylate-butyl acrylate-styrene polymer
  • calcium zinc stabilizer zinc stabilizer
  • ADC foaming agent yellow foam
  • NC foaming agent white foaming
  • high-temperature lubricating oxidized polyethylene wax
  • WPC wood-plastic flooring also has its own characteristics in the following performance:
  • the appearance of texture with the natural appearance and texture of wood. It has better dimensional stability than wood, no wood knots, no cracks, warpage and deformation.
  • the product can be made into a variety of colors, and the surface does not need secondary paint to last for a long time.
  • Processing performance It has the secondary processing property of wood, such as sawing, planing, bonding, fixing with nails or screws, standard specifications of various profiles, and quick and convenient construction and installation. Through a variety of operations, it can be processed into various facilities and products.
  • the base material layer 110 can also be composed of a wood substrate including wood powder, a board not including wood powder, a PVC wood plastic floor, a PVC stone plastic floor, and the like. . Considering that the substrate layer 110 needs to have both water repellency, moisture resistance, high temperature resistance, low temperature resistance and the like, the WPC wood plastic floor and the SPC stone plastic floor are preferred embodiments.
  • the hard material can be selected from tiles or stone.
  • the main components of ceramic tiles are clay, quartz, feldspar and other three types of mining materials and some chemical raw materials.
  • clay kaolin
  • the main chemical component is Al 2 O 3 , which plays a role in plasticity and bonding during production to ensure the strength of the dry billet and various performances after firing.
  • Quartz (silica sand) is an inert material that is viscous.
  • the main chemical component, SiO 2 reduces the viscosity of the blank.
  • part of the quartz is dissolved in the feldspar glass to increase the viscosity of the liquid phase, prevent high temperature deformation, and act as a skeleton in the porcelain blank after cooling.
  • Feldspar (stone powder) is a flux raw material.
  • the main chemical components are K 2 O, Na 2 O, CaO, MgO.
  • Glaze is a colorless or colored glassy layer covering the surface of ceramic products. It is made of mineral raw materials (feldspar, quartz, talc, kaolin, etc.) and chemical raw materials in a certain proportion (some raw materials can be made into frit first)
  • Stone can be divided into natural stone and artificial stone. Natural stone is often used for laying marble on the ground.
  • the artificial stone is made of quartz stone.
  • the marble material is CaCO 3 , the main component of limestone, and the main component of quartz is SiO 2 .
  • Marble is used as a building material, and quartz stone is made of quartz sand, quartz refractory and artificial stone. Marble is a natural stone with uneven texture and gaps or small holes. Marble may have radiation or harmful substances. Regardless of the above types of stone, it has the characteristics of compact structure, good compressive strength, natural texture, heavy texture, solemn majesty, minimal linear expansion coefficient, good rigidity, high hardness, strong wear resistance and small temperature deformation. And maintenance, maintenance is simple and convenient, long service life, no magnetization, no stagnation, no moisture, flat surface.
  • the base material layer 110 has a good toughness, a small shape variable after being affected by temperature, and the wear layer 120 has a high hardness but is susceptible to cracking by external stress.
  • the substrate layer 110 can act as an auxiliary mounting layer of the wear layer 120, and the wear layer 120 further increases the pressure resistance and deformation resistance of the substrate layer 110. Therefore, further, on the substrate layer 110, a fixing member is further provided, and the fixing member may be integrally formed with the substrate layer 110, or may be additionally installed, and disposed on both sides of the substrate layer 110, when the user needs When two pieces and two or more composite sheets 100 are joined, it is only necessary to fix one side (for example, the left side) of the base material layer 110 of the composite sheet 100 to the base layer 110 of the adjacent composite sheet 100.
  • the fixing elements on the opposite side (for example, the right side) can be fixed to each other to fix the relative positions of the two composite sheets 100. It can be understood that during the installation process, the wear layer 120 no longer needs to be coated with an adhesive, and the required materials, mounting surfaces, etc. of the paving will be completed by the substrate layer 110, which greatly saves labor costs. And time cost.
  • the base material layer 110 and the wear layer 120 can be press-formed at a high temperature, or coated with a binder, and formed by low-temperature cold pressing.
  • the above molding process can be performed at the manufacturing plant of the composite sheet 100 without requiring the user to operate at the installation site.
  • the first composite sheet 100 is placed from the upper left corner of the room having the paving surface according to the shape of the substrate layer 110, and the fixing member is exposed outward.
  • a certain gap should be reserved between the ground and the wall. The larger the area to be laid, the wider the gap should be reserved.
  • the fixing elements of the second composite sheet 100 are inserted into the fixing members of the first composite sheet 100.
  • other composite panels 100 are installed along the first row, and so on, all of the composite panels 100 are installed.
  • the composite sheet 100 further includes a first bonding layer 140 bonded between the substrate layer 110 and the wear layer 120.
  • the first bonding layer 140 may be a PVC layer for increasing the flexibility of the substrate layer 110.
  • the composite sheet 100 may further include a substrate layer 130 disposed on the other side of the substrate layer 110 relative to the wear layer 120, ie, the wear layer 120 and the substrate layer 130 are disposed on the substrate layer On both sides of the 110.
  • the substrate layer 130 is also relatively fixed to the substrate layer 110. After the substrate layer 130 is selected, it may be an IXPE plastic layer, an EVA, a Cork cork layer, etc., for reducing noise and increasing the softness of the composite board 100.
  • the composite panel 100 may further include a second bonding layer 150 bonded to the substrate layer 110 and the substrate layer. 130, or in an embodiment without the substrate layer 130, is mounted on the paving surface by the second bonding layer 150.
  • the second bonding layer 150 may also be a PVC layer.
  • the PVC layer is bonded to the paving surface by an adhesive. The bonding strength between the PVC layer and the ground makes the overall structural bonding of the composite panel 100 more secure.
  • the fixing component disposed on the substrate layer 110 is a locking component 111
  • the locking component 111 is a pair of latches integrally formed with a WPC wood-plastic floor or a SPC stone-plastic floor, each pair
  • the locking elements 111 are respectively disposed on both sides of the substrate layer 110, that is, on both sides of each of the substrate layers 110, asymmetric components such as the mounting groove 112 and the mounting rib 113 are provided as a substrate layer.
  • the mounting ribs 113 of the 110 are inserted into the mounting slots 112 of the adjacent blocks, the mounting ribs 113 will be mated with the mounting slots 112 such that the adjacent substrate layers 110 are also relatively fixed to each other.
  • the mounting rib 113 of the locking element 111 further includes a limiting groove 114, and the surface of the mounting groove 112 protrudes to form a limiting rib 115.
  • the mounting groove 112 is fitted with the mounting rib 113, the mounting groove is usually installed.
  • the notch of the 112 is designed to be smaller than the end of the mounting rib 113. Therefore, the mounting rib 113 cannot be inserted into the mounting groove 112 along the opening direction of the notch itself, and needs to be inserted laterally along the groove direction of the mounting groove 112, thereby utilizing the groove.
  • the size of the port and the mounting rib 113 is such that the mounting rib 113 is engaged in the mounting groove 112.
  • the limiting rib 115 will also be inserted into the limiting slot 114 when laterally inserted, thereby further limiting the axial and radial displacement between the substrate layers 110.
  • the cross-sectional shape of the mounting groove 112 and the mounting rib 113, the limiting groove 114, and the limiting rib 115 may have various irregular shapes such as an approximately trapezoidal shape or an approximately triangular shape.
  • the mounting groove 112 and the mounting rib 113, the limiting groove 114 and the limiting rib 115 are in contact with each other at a partial position, and a gap is left between the two positions for heat deformation, and the installation and disassembly are also convenient.
  • the base material layer 110 and the wear layer 120 are each formed in a regular rectangular shape.
  • the base material layer 110 faces the wear layer 120 as a mounting surface, and the wear layer 120 is mounted on the mounting surface of the base material layer 110 to form a composite sheet.
  • the size of the wear layer 120 is less than or equal to the mounting surface of the substrate layer 110 such that a pair of opposite edges of the wear layer 120 fits against the opposite edges of the mounting surface when the composite sheet 100 is mounted on the ground or On the wall surface, the pair of opposite edges of the substrate layer 110 cannot be seen when viewed in a direction perpendicular to the ground or the wall.
  • the other pair of opposite edges of the wear layer 120 When the other pair of opposite edges of the wear layer 120 are disposed, the other pair of opposite edges of the substrate layer 110 may be selected to be attached, or more inward, such that the other pair of opposite edges are disposed on the mounting surface.
  • the base layer 110 of the two composite sheets 100 is closely adhered, and a certain gap is left between the wear-resistant layers 120 for filling the filler or for preserving the tile. Sewing 121 (beauty seam).
  • the opposite edges described above mean a pair of opposing long or short sides on the substrate layer 110 and the wear layer 120. If the substrate layer 110 and/or the wear layer 120 itself is of an irregular shape, the opposite edges may be adjacent or non-adjacent straight segments or curved segments.
  • the wear layer 120 may also be formed by multiple pieces or integrally formed.
  • a gap is reserved between the wear layers 120 .
  • the function is the decorative slit 121; when integrally formed, the surface of the wear-resistant layer 120 is provided with a recessed decorative slit 121, and the decorative slit 121 is parallel to the width direction of the wear-resistant layer 120.
  • a structure in which a plurality of wear-resistant layers 120 are formed by a predetermined opening of a decorative slit 121 on a base material layer 110 in FIG. 11 is provided.
  • a single-piece base material layer 110 is provided.
  • the single wear layer 120 has a pre-configured molding effect at the time of manufacture, which simplifies the user's installation process.
  • the invention also discloses a manufacturing method of a composite board, which comprises the following steps:
  • Step S100 taking a substrate layer as a core of the composite sheet
  • Step S200 opening fixing elements on both sides of the substrate layer, and fixing components on the substrate layer of the adjacent composite sheet are mutually fitted, and the composite sheet can be relatively fixed;
  • Step S300 laying a wear layer on the substrate layer and fixing it on the substrate layer. Since the wear layer and the substrate layer are relatively fixed, after the base layer is installed, the position of the wear layer is also fixed together, thereby realizing that the wear layer itself does not need to be configured and installed, and the base layer can be completed.
  • the basic requirement is that the overall thickness of the plurality of composite sheets is the same, and the thickness of the base layer and the wear layer of the composite sheet laid on the same pavement surface is the same. It is basically the same.
  • the substrate layer is used for fixed installation, instead of the thickness of the existing tile, a part of the thickness can be replaced, that is, a part of the tile is replaced, so that the thickness of the composite plate is not increased compared with the thickness of the existing tile. That is, there is no problem of reducing the height reduction of the user's indoor space.

Abstract

一种复合板材（100）及其制造方法。复合板材，包括：基材层（110），形成复合板材的板材芯；耐磨层（120），覆于基材层上，并与基材层相对固定，其中基材层还包括固定元件(111)，固定元件设于基材层的两侧，当至少两块复合板材连接时，固定元件互相结合，以相对固定复合板材。采用上述技术方案后，复合板材既具有如瓷砖的硬度和耐磨性，同时基材层可用作复合板材的安装，提高瓷砖的安装效率，减少安装时的人工成本。

Description

一种复合板材及其制造方法 技术领域
本发明涉及建筑耗材领域，尤其涉及一种复合板材及其制造方法。
背景技术
在建筑耗材领域中，铺设在地面或墙面上的板材，通常具有防水性、防潮性、成本低、不易变形等特点。对此，市面上多采用纤维板或颗粒板的层压地板，或是瓷砖、石材等硬质材料，根据用户不同的需求，选择木板板材、塑料板材、硬质板材等铺设在地板或墙面上。
当用户使用如瓷砖、石材等硬质材料时，虽然材料本身具有美化器物、便于拭洗、不被尘土腥秽侵蚀等特点，但由于硬度较高，韧性较差，可承受的外部形变量较少。若瓷砖、石材收到外部应力时，将裂开或破碎，因此，在安装瓷砖、石材在墙面或地面上时，通常采用人工铺设并利用粘合剂、水泥等粘合的方式，且在瓷砖、石材的本体上，切割完成后或切割时也不具备额外开设用于互相固定的结构。
而若使用常见的基材代替瓷砖、石材等，虽然基材具有更高的韧性，但相应地，其硬度较差，表面受到刮滑容易产生划痕，影响美观。
因此，需要一种新型的复合板材，其既具有如瓷砖的硬度和耐磨性，同时也具有板材的芯层，可用作复合板材的安装，提高瓷砖的安装效率，减少人工成本。此外，也保持瓷砖和基材原有的防水性和耐热性。
发明内容
为了克服上述技术缺陷，本发明的目的在于提供一种复合板材及其制造 方法，在瓷砖等铺装的过程中，减少粘结剂的使用量及其带来的有害物质，可起到绿色安装的效果。同时，各部分各为其用，为家装行业带来产品线的新冲击。
本发明公开了一种复合板材，包括：
基材层，形成所述复合板材的板材芯；
耐磨层，覆于所述基材层上，并与所述基材层相对固定，其中
所述基材层还包括固定元件，所述固定元件设于所述基材层的两侧，当至少两块复合板材连接时，所述固定元件互相结合，以相对固定所述复合板材。
优选地，所述基材层包括石粉和塑料的复合物；
所述耐磨层包括硬质材料。
优选地，所述复合物为WPC木塑地板或SPC石塑地板；
所述硬质材料为瓷砖或石材。
优选地，所述基材层与所述耐磨层粘结后高温或冷压成型。
优选地，所述复合板材还包括：
第一结合层，粘结于所述基材层与耐磨层间。
优选地，所述复合板材还包括：
衬底层，设于所述基材层相对于所述耐磨层的另一侧上，并与所述基材层相对固定。
优选地，所述复合板材还包括：
第二结合层，粘结于所述基材层与衬底层间。
优选地，所述固定元件为锁扣元件；
所述锁扣元件包括分设在所述基材层两侧的安装槽与安装筋，安装筋与所述安装槽匹配卡合以固定多个所述基材层。
优选地，所述安装筋还包括限位槽，所述安装槽的表面突出形成有限位筋；
所述限位筋与所述限位槽匹配卡合，以限制多个所述基材层间的轴向及 径向位移。
优选地，所述基材层包括面向所述耐磨层的安装面；
所述耐磨层的一对相对边缘与所述安装面的相对边缘贴合，另一对相对边缘设于所述安装面的射影范围内。
优选地，所述耐磨层的表面预开设有装饰缝；
所述装饰缝与所述耐磨层的宽度方向平行。
本发明还公开了一种复合板材的制造方法，包括以下步骤：
步骤S100：取一基材层作为复合板材的板材芯；
步骤S200：在所述基材层的两侧，开设固定元件，用于相对固定复合板材；
步骤S300：在所述基材层上铺设一耐磨层，并固定在所述基材层上。
采用了上述技术方案后，与现有技术相比，具有以下有益效果：
1.解决了瓷砖或石材等硬度较大的材料作为建筑耗材时的铺装难题，大大节约了人力成本和时间成本；
2.瓷砖铺装时，减少了粘合剂的使用量及使用粘合剂时产生的有害物质，符合绿色装饰的趋势；
3.在不增加复合板材的厚度的基础上，可同时利用耐磨层的硬度和基材层的韧性，形成可应用在任何场合的近乎完美的复合板材；
4.基材层本身的防水、防潮、防形变等特性，使得本发明中的复合板材可在收到温度的异常变化时，不会过多的形变，影响复合板材原本的结构。
附图说明
图1为符合本发明一优选实施例中复合板材的结构示意图；
图2为符合本发明一优选实施例中具有第一结合层的复合板材的结构示意图；
图3为符合本发明一优选实施例中具有第二结合层的复合板材的结构示意图；
图4为符合本发明一优选实施例中同时具有第一结合层和第二结合层的复合板材的结构示意图；
图5为符合本发明一优选实施例中复合板材的基材层上的锁扣元件的结构示意图；
图6为符合本发明另一优选实施例中复合板材的基材层上的锁扣元件的结构示意图；
图7为符合本发明又一优选实施例中复合板材的基材层上的锁扣元件的结构示意图；
图8为符合本发明又一优选实施例中复合板材的基材层上的锁扣元件的结构示意图；
图9为符合本发明又一优选实施例中复合板材的基材层上的锁扣元件的结构示意图；
图10为符合本发明又一优选实施例中复合板材的基材层上的锁扣元件的结构示意图；
图11为符合本发明一优选实施例中具有装饰缝的复合板材的结构示意图；
图12为符合本发明另一优选实施例中具有装饰缝的复合板材的结构示意图。
附图标记：
100-复合板材；
110-基材层、111-锁扣元件、112-安装槽、113-安装筋、114-限位槽、115-限位筋；
120-耐磨层、121-装饰缝；
130-衬底层；
140-第一结合层；
150-第二结合层。
具体实施方式
以下结合附图与具体实施例进一步阐述本发明的优点。
这里将详细地对示例性实施例进行说明，其示例表示在附图中。下面的描述涉及附图时，除非另有表示，不同附图中的相同数字表示相同或相似的要素。以下示例性实施例中所描述的实施方式并不代表与本公开相一致的所有实施方式。相反，它们仅是与如所附权利要求书中所详述的、本公开的一些方面相一致的装置和方法的例子。
在本公开使用的术语是仅仅出于描述特定实施例的目的，而非旨在限制本公开。在本公开和所附权利要求书中所使用的单数形式的“一种”、“所述”和“该”也旨在包括多数形式，除非上下文清楚地表示其他含义。还应当理解，本文中使用的术语“和/或”是指并包含一个或多个相关联的列出项目的任何或所有可能组合。
应当理解，尽管在本公开可能采用术语第一、第二、第三等来描述各种信息，但这些信息不应限于这些术语。这些术语仅用来将同一类型的信息彼此区分开。例如，在不脱离本公开范围的情况下，第一信息也可以被称为第二信息，类似地，第二信息也可以被称为第一信息。取决于语境，如在此所使用的词语“如果”可以被解释成为“在……时”或“当……时”或“响应于确定”
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和简化描述，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。
在本发明的描述中，除非另有规定和限定，需要说明的是，术语“安装”、“相连”、“连接”应做广义理解，例如，可以是机械连接或电连接，也可以是两个元件内部的连通，可以是直接相连，也可以通过中间媒介间接相连，对于本领域的普通技术人员而言，可以根据具体情况理解上述术语的具体含 义。
在后续的描述中，使用用于表示元件的诸如“模块”、“部件”或“单元”的后缀仅为了有利于本发明的说明，其本身并没有特定的意义。因此，“模块”与“部件”可以混合地使用。
参阅图1，为符合本发明一优选实施例中复合板材100的结构示意图。该实施例中，复合板材100包括了两个主要的基层，分别为基材层110及耐磨层120。基材层110作为复合板材100的板材芯，配置在复合板材100的中间部分，或是作为底层与需要铺装复合板材100的地面或墙面粘结贴合。耐磨层120覆盖在基材层110上，并通过粘结剂或其他不使用粘结剂的加工方式，固定在基材层110上，使得本发明的复合板材100至少由基材层110及耐磨层120组成。更具体地，耐磨层120面向铺设复合地板的地面或墙面的外部，并直接与家具、用户等接触摩擦，其表面可选地再覆有防滑膜、耐磨膜、亚光膜等，用以加强耐磨效果或装饰效果等。
在一优选实施例中，基材层110包括石粉和塑料的复合物，亦或是普通的木材地板等，也可以是包括竹屑、木屑、软木屑或混合物的压制屑类材料，也可以是不包括屑类材料的高密度聚乙烯材料，或是原生PVC、循环PVC或两者的组合。无论采用上述何种成分，在使用的材料混合后，复合材料被压制成型为复合板材100。同样地，耐磨层120包括硬质材料，或是主要由硬质材料组成，并混合有其他的添加材料。
更为具体地，基材层110包括的复合物为WPC木塑地板或SPC石塑地板。SPC石塑地板主要成分包括有聚氯乙烯、碳酸钙、稳定剂、黄发泡(ADC发泡剂)、白发泡(NC发泡剂)、以及其他化学助剂，如润滑剂、抗菌剂、稳定剂、调色剂、抗UV剂、结合剂中的一种或多种等。SPC石塑地板制造时，经由挤出机结合T型模具挤出PVC基材，用三辊或四辊压延机分别把PVC耐磨层、PVC彩膜和PVC基材，一次性加热贴合、压纹后成型，工艺简单、贴合靠热量完成，不需要胶水。更具体地，可通过以下工序完成制备：
1.混料
按照材料配比计量后，导入高速混合机热混，热混温度可以是125℃，用于使得各种材料混合均匀，排除材料中的水分，热混后进入冷混，用于给物料降温，防止结块和变色，冷混温度可以是55℃，最后冷却混合均匀的材料。
2.挤出
将物料加入双螺杆挤出机，进行加热挤出，而后进入片材模头挤出成型，成型的片材经过四辊压延机，基材进行定厚，并通过多步骤的贴彩膜、贴耐磨层120(本发明中可省略)后冷却，最后切割成型。
3.UV回火
切割成型后的物料进行表面UV，并回火的工序，其中回火所用热水温度在80～120℃间，冷水温度约为10℃。
4.分切开槽+包装
最后，分切物料，并开槽、修边、倒角，检验完成后便可包装运输。
SPC石塑地板所使用的材料环保，不含重金属、邻苯二甲酸酯、甲醇等有害物质，且100％不含甲醛。结构上，SPC石塑地板厚度仅4-5.5毫米，无毒无味，不怕水、不怕火、不怕潮；耐刮性能上，资源使用上，防滑性能上，SPC石塑地板均优于强化地板。除上述基本性质外，SPC石塑地板还具有收缩率：≤1‰(回火处理后)，≤2.5‰(回火处理前)的特性，且其地板密度约在1.9～2吨/立方米，使其物理指标稳定可靠、化学指标符合国际、国家标准。
若使用WPC木塑地板作为复合物，WPC为Wood Plastic Composition的简称，是一种主要由木材(木纤维素、植物纤维素)为基础材料与热塑性高分子材料(塑料)和加工助剂等，混合均匀后再经模具设备加热挤出成型而制成的材料，兼有木材和塑料的性能与特征。除上述基本成分外，WPS木塑地板还包括：发泡调节剂(甲基丙烯酸甲酯-丙烯酸丁酯-苯乙烯聚合物)、钙锌稳定剂(硬脂酸锌，硬脂酸钙)、内润滑60、PE蜡(费托蜡)、黄发泡(ADC发泡剂)、白发泡(NC发泡剂)、高温润滑(氧化聚乙烯蜡)中的任 意一种或多种。WPC木塑地板由于拥有和木材一样的加工特性，使用普通的工具即可锯切、钻孔、上钉，非常方便，可以像普通木材一样使用。同时具有木材的木质感和塑料的耐水防腐特性，使得它成为一种性能优良并十分耐用的室外防水防腐建材。
此外，在以下性能上，WPC木塑地板也同样具有自身特性：
1、物理性能：强度好、硬度高、防滑、耐磨、不开裂、不虫蛀，吸水性小、耐老化、耐腐蚀、抗静电和紫外线、绝缘、隔热、阻燃、可抗75℃高温和-40℃的低温。
2、环保性能：生态木、环保木、可再生，不含有毒物质，危险的化学成分、防腐剂等，无甲醛、苯等有害物质释放，不会造成空气污染及环境污染，能100％回收再利用并重新加工使用，也可生物降解。
3、外观质感：具有木材的自然外观、质感。比木材尺寸稳定性好，无木材节疤，不会产生裂纹、翘曲、变形，产品可制成多种颜色，表面无须二次淋漆亦可长久保新不退色。
4、加工性能：具有木材的二次加工性，如可锯、可刨、粘结、用钉子或螺钉固定，各种型材规范标准,施工安装快捷方便。通过常规作业方式，可加工成各种设施和制品。
除上述WPC木塑地板和SPC石塑地板地板外，可以理解的是，基材层110也可由包括木粉的木材基板、不包括木粉的板材、PVC木塑地板、PVC石塑地板等组成。考虑到该基材层110需要同时兼具防水性、防潮性、耐高温、耐低温等性质，WPC木塑地板和SPC石塑地板为较佳的实施方式。
对应地，硬质材料可选为瓷砖或石材。瓷砖的主要成分为粘土、石英、长石等三大类矿山原料和一些化工原料。其中，粘土(高岭土)为可塑性物质，主要化学成份Al 2O 3，它们在生产中起塑性和结合作用，保证干坯强度及烧成后的各种使用性能。石英(硅砂)属于瘠性材料，减粘物质。主要化学成份SiO 2，它可降低坯料粘性。烧成中，部分石英溶解在长石玻璃中，提高液相粘度，防止高温变形，冷却后在瓷坯中起骨架作用。长石(石粉)属 于熔剂原料。主要化学成分K 2O、Na 2O、CaO、MgO。高温下熔融后可以溶解一部分石英及高岭土分解物，熔融后的高粘度玻璃可以起到高温胶结作用。釉是覆盖在陶瓷制品表面的无色或有色的玻璃质薄层，是用矿物原料(长石、石英、滑石、高岭土等)和化工原料按一定比例配合(部分原料可先制成熔块)经过研磨制成釉浆，施于坯体表面，经一定温度煅烧而成。能增加制品的机械强度、热稳定性和电介强度，还有美化器物、便于拭洗、不被尘土腥秽侵蚀等特点。
石材中可分为天然石和人造石，天然石常用于地面铺设的有大理石，人造石中地面使用的为石英石。大理石材质是石灰岩主要成分CaCO 3，石英就是种材质主要成分是SiO 2。大理石多做建筑材料，石英石多做石英砂、石英耐火材料和人造石板材。大理石为天然石材，质地不均匀有缝隙或小孔，大理石可能会有辐射或对人体有害物质。无论上述何种类型的石材，其均具有结构致密，抗压强度好、纹理自然、质感厚重、庄严雄伟、线胀系数极小、刚性好、硬度高、耐磨性强、温度变形小等特点，并且维护，保养方便简单、使用寿命长、不磁化、无滞涩感、不受潮湿影响、平面称定好。
由于现有硬质材料的上述性质，安装时，需要在瓷砖、石材的下部安装面涂覆粘结剂、水泥等安装在铺装面上，安装时需要安装人员先行在铺装面上涂上粘结剂水泥后，再根据地面或墙面的设计，逐一地铺装瓷砖，安装耗时极长且繁琐。因此，根据上述实施例中基材层110具有的韧性好，受温度影响后形变量小的特点，以及耐磨层120具有硬度高，但受外部应力易裂开的特点。两者结合后，基材层110可作用为耐磨层120的辅助安装层，耐磨层120更进一步地增加基材层110的抗压和抗形变能力。因而，更进一步地，在基材层110上，还设置有固定元件，固定元件可与基材层110一体成型，或是额外加装，其设置在基材层110的两侧，当用户需要将两块以及两块以上的复合板材100连接时，只需将复合板材100的基材层110上的一侧(例如左侧)的固定元件，与相邻的复合板材100的基材层110上的相对一侧(例如右侧)的固定元件，相互配合安装后，便可固定两块复合板材100的相对 位置。且可以理解的是，在安装过程中，耐磨层120不再需要涂覆粘结剂，铺装所需的材料、安装面等，将均由基材层110完成，极大地节约了人力成本和时间成本。
在对复合板材100成型时，基材层110与耐磨层120间可高温压制成型，亦或是涂覆有粘结剂，并低温冷压成型。上述成型过程可以在复合板材100的制造工厂完成，无需用户在安装现场再行操作。而铺装有复合板材100的地面或墙面，可选用自流平或者找平整地面；例如：水泥地面，水磨石地面，瓷砖、大理石及木地板地面，并在安装前除去地面和墙面油污，粉尘等，做到清洁无残渣。安装复合板材100时，可根据基材层110的形状，从具有铺装面的房间的左上角开始，放置第一块复合板材100，将固定元件向外露出。为了防止复合地板的可能出现的自然膨胀，地面和墙面之间应预留一定的间隙。铺设的面积越大，预留的间隙应越宽。在铺设第一排的第二块复合板材100时，将第二块复合板材100的固定元件插入到第一块复合板材100的固定元件内。继续使用上述方法，沿第一排安装其他复合板材100，并以此类推，完成所有复合板材100的安装。
参阅图2-图4，分别示出了不同实施例中复合板材100具有的其他基层。如图2所示，复合板材100还包括有第一结合层140，粘结在基材层110与耐磨层120间。第一结合层140可以是PVC层，用于增加基材层110的柔韧性。
优选地或可选地，复合板材100还可包括衬底层130，其设置在基材层110相对于耐磨层120的另一侧上，即耐磨层120和衬底层130分设在基材层110的两侧。衬底层130同样地与基材层110相对固定。衬底层130可选用后，可以为IXPE塑料层、EVA、Cork软木层等，用于减少噪音，增加复合板材100的柔软度。
参阅图3及图4，在具有第一结合层140或不具有第一结合层140的不同实施例中，复合板材100还可包括第二结合层150，粘结在基材层110和衬底层130间，或是在不具有衬底层130的实施例中，通过第二结合层150， 安装在铺装表面上。第二结合层150也可以是PVC层，通过粘结剂将PVC层粘合在铺装表面上，利用PVC层和地面之间的胶合强度，使得复合板材100的整体结构粘合更加牢固。
在另一优选实施例中，基材层110上设置的固定元件为锁扣元件111，锁扣元件111为与如WPC木塑地板或SPC石塑地板一体成型的成对锁扣，每一对锁扣元件111分别设置在基材层110的两侧，也就是说，每一个基材层110的两侧，设有不对称的元件，如安装槽112与安装筋113，当一块基材层110的安装筋113插入相邻块的安装槽112内时，安装筋113将与安装槽112匹配卡合，使得相邻的基材层110也互为相对固定。
参阅图5-10，分别示出了不同实施例中锁扣元件111的结构。根据图示的实施例，锁扣元件111的安装筋113还包括有限位槽114，安装槽112的表面突出形成有限位筋115，当安装槽112与安装筋113配合安装时，由于通常安装槽112的槽口设计的小于安装筋113的端部大小，因此，沿槽口本身的开口方向，无法将安装筋113插入安装槽112，需要沿安装槽112的开槽方向横向插入，从而利用槽口和安装筋113的大小关系，将安装筋113卡合在安装槽112内。同时，基于限位槽114和限位筋115的开设，在横向插接时，限位筋115也将卡入限位槽114内，进一步限制基材层110间的轴向及径向位移。安装槽112和安装筋113、限位槽114和限位筋115的截面形状，可以有多种不规则形状，如近似梯形或近似三角形。且可以理解的是，安装槽112与安装筋113、限位槽114与限位筋115在部分位置接触，部分位置两者间留有空隙，供受热形变预留，同时也方便安装和拆卸。
参阅图11，基材层110和耐磨层120均呈规则的长方形，基材层110面向耐磨层120为一安装面，耐磨层120安装在基材层110的安装面上形成复合板材100的整体结构时，耐磨层120的大小小于或等于基材层110的安装面，使得耐磨层120的一对相对边缘与安装面的相对边缘贴合，当复合板材100安装在地面或墙面上时，从垂直于地面或墙面的方向上观察，无法看到基材层110的这对相对边缘。而在耐磨层120的另一对相对边缘设置时，可 以选择与基材层110的另一对相对边缘贴合，或是更为靠内，使得另一对相对边缘设置在安装面的射影范围内，则相邻的复合板材100安装完成后，两复合板材100的基材层110紧密贴合，耐磨层120间留有一定的缝隙，供填充填充物，或是留作瓷砖的装饰缝121(美缝)用。
上文所述的相对边缘，意指基材层110及耐磨层120上，一对相对的长边或短边。若基材层110和/或耐磨层120本身为不规则形状，则相对边缘可以是相邻或不相邻的直线段或曲线段。
继续参阅图11，耐磨层120也可以是多块拼接成型，或是一体成型，多块耐磨层120在一块基材层110上粘结拼接时，耐磨层120间预留有间隙，作用为装饰缝121；一体成型时，耐磨层120的表面开设有凹陷的装饰缝121，且装饰缝121与耐磨层120的宽度方向平行。具有上述配置，对于用户而言，在铺装本发明的复合板材100后，无需再另外开设装饰缝121，也就是说，原本在铺装瓷砖时需要的多部工序，全部在复合板材100的生产过程中完成，大大节约了用户的人工成本和时间成本。
参阅图12，不同于图11中一块基材层110上通过装饰缝121的预先开设隔开形成了多块耐磨层120的结构，在该图示中，单块基材层110上设有单块耐磨层120，安装完成后的成型效果在生产制造时便已预先配置好，更加简化用户的安装过程。
本发明还公开了一种复合板材的制造方法，具体包括以下步骤：
步骤S100：取一基材层作为复合板材的板材芯；
步骤S200：在基材层的两侧，开设固定元件，相邻复合板材的基材层上的固定元件相互配合安装，可相对固定复合板材；
步骤S300：在基材层上铺设一耐磨层，并固定在基材层上。由于耐磨层与基材层相对固定，基材层安装完毕后，耐磨层的位置也一同固定，从而实现了耐磨层本身无需配置安装的结构，交由基材层完成即可。
在上述制造方法中，可以理解的是，建筑行业本身最基本的要求，多块复合板材的整体厚度相同，则铺装在同一铺装面上的复合板材的基材层和耐 磨层的厚度也基本相同。且由于基材层用以固定安装，与现有瓷砖的厚度相比，可代替其中部分厚度，即替换一部分的瓷砖，使得复合板材的厚度与现有瓷砖的厚度相比，不会额外增加，即不会出现减少用户室内空间层高降低的问题。
应当注意的是，本发明的实施例有较佳的实施性，且并非对本发明作任何形式的限制，任何熟悉该领域的技术人员可能利用上述揭示的技术内容变更或修饰为等同的有效实施例，但凡未脱离本发明技术方案的内容，依据本发明的技术实质对以上实施例所作的任何修改或等同变化及修饰，均仍属于本发明技术方案的范围内。

Claims (12)

  1. 一种复合板材，其特征在于，包括：
    基材层，形成所述复合板材的板材芯；
    耐磨层，覆于所述基材层上，并与所述基材层相对固定，其中
    所述基材层还包括固定元件，所述固定元件设于所述基材层的两侧，当至少两块复合板材连接时，所述固定元件互相结合，以相对固定所述复合板材。
  2. 如权利要求1所述的复合板材，其特征在于，
    所述基材层包括石粉和塑料的复合物；
    所述耐磨层包括硬质材料。
  3. 如权利要求2所述的复合板材，其特征在于，
    所述复合物为WPC木塑地板或SPC石塑地板；
    所述硬质材料为瓷砖或石材。
  4. 如权利要求1所述的复合板材，其特征在于，
    所述基材层与所述耐磨层粘结后高温或冷压成型。
  5. 如权利要求1所述的复合板材，其特征在于，
    所述复合板材还包括：
    第一结合层，粘结于所述基材层与耐磨层间。
  6. 如权利要求1或5所述的复合板材，其特征在于，
    所述复合板材还包括：
    衬底层，设于所述基材层相对于所述耐磨层的另一侧上，并与所述基材层相对固定。
  7. 如权利要求6所述的复合板材，其特征在于，
    所述复合板材还包括：
    第二结合层，粘结于所述基材层与衬底层间。
  8. 如权利要求1所述的复合板材，其特征在于，
    所述固定元件为锁扣元件；
    所述锁扣元件包括分设在所述基材层两侧的安装槽与安装筋，安装筋与所述安装槽匹配卡合以固定多个所述基材层。
  9. 如权利要求8所述的复合板材，其特征在于，
    所述安装筋还包括限位槽，所述安装槽的表面突出形成有限位筋；
    所述限位筋与所述限位槽匹配卡合，以限制多个所述基材层间的轴向及径向位移。
  10. 如权利要求1所述的复合板材，其特征在于，
    所述基材层包括面向所述耐磨层的安装面；
    所述耐磨层的一对相对边缘与所述安装面的相对边缘贴合，另一对相对边缘设于所述安装面的射影范围内。
  11. 如权利要求1所述的复合板材，其特征在于，
    所述耐磨层的表面预开设有装饰缝；
    所述装饰缝与所述耐磨层的宽度方向平行。
  12. 一种复合板材的制造方法，其特征在于，包括以下步骤：
    步骤S100：取一基材层作为复合板材的板材芯；
    步骤S200：在所述基材层的两侧，开设固定元件，用于相对固定复合板材；
    步骤S300：在所述基材层上铺设一耐磨层，并固定在所述基材层上。
PCT/CN2018/083119 2018-04-13 2018-04-13 一种复合板材及其制造方法 WO2019196122A1 (zh)

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US9938726B2 (en) * 2016-08-26 2018-04-10 Quickstyle Industries Inc. Densified foam core (DFC) tile with imitation grout line
NL2025165B1 (en) * 2020-03-19 2021-10-20 I4F Licensing Nv Tile panel, and a surface covering constructed by a multitude of neighbouring tile panels
US20230141438A1 (en) * 2020-03-19 2023-05-11 I4F Licensing Nv Tile Panel, and a Surface Covering Constructed by a Multitude of Neighbouring Tile Panels
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