WO2025118518A1 - 一种板材、静音地板及其制作方法 - Google Patents

一种板材、静音地板及其制作方法 Download PDF

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Publication number
WO2025118518A1
WO2025118518A1 PCT/CN2024/097971 CN2024097971W WO2025118518A1 WO 2025118518 A1 WO2025118518 A1 WO 2025118518A1 CN 2024097971 W CN2024097971 W CN 2024097971W WO 2025118518 A1 WO2025118518 A1 WO 2025118518A1
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WIPO (PCT)
Prior art keywords
layer
doping
glass magnesium
mesh
stretching
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Pending
Application number
PCT/CN2024/097971
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English (en)
French (fr)
Inventor
雷响
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Anhui Yangzi Flooring Co Ltd
Anhui Yangzi Meijia New Material Technology Co Ltd
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Anhui Yangzi Flooring Co Ltd
Anhui Yangzi Meijia New Material Technology Co Ltd
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Publication of WO2025118518A1 publication Critical patent/WO2025118518A1/zh
Anticipated expiration legal-status Critical
Pending legal-status Critical Current

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Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/02—Flooring or floor layers composed of a number of similar elements
    • E04F15/10—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials
    • E04F15/107—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials composed of several layers, e.g. sandwich panels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B13/00—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material
    • B32B13/02—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material with fibres or particles being present as additives in the layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B13/00—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material
    • B32B13/04—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material comprising such water setting substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B13/12—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material comprising such water setting substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B13/00—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material
    • B32B13/14—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B21/00—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board
    • B32B21/02—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board the layer being formed of fibres, chips, or particles, e.g. MDF, HDF, OSB, chipboard, particle board, hardboard
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B21/00—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board
    • B32B21/04—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B21/06—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood as the main or only constituent of a layer, which is next to another layer of the same or of a different material of paper or cardboard
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B21/00—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board
    • B32B21/04—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B21/08—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B32B27/306—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising vinyl acetate or vinyl alcohol (co)polymers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/02—Flooring or floor layers composed of a number of similar elements
    • E04F15/04—Flooring or floor layers composed of a number of similar elements only of wood or with a top layer of wood, e.g. with wooden or metal connecting members
    • E04F15/041—Flooring or floor layers composed of a number of similar elements only of wood or with a top layer of wood, e.g. with wooden or metal connecting members with a top layer of wood in combination with a lower layer of other material
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/18—Separately-laid insulating layers; Other additional insulating measures; Floating floors
    • E04F15/181—Insulating layers integrally formed with the flooring or the flooring elements
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/18—Separately-laid insulating layers; Other additional insulating measures; Floating floors
    • E04F15/20—Separately-laid insulating layers; Other additional insulating measures; Floating floors for sound insulation
    • E04F15/206—Layered panels for sound insulation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/101—Glass fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/10—Properties of the layers or laminate having particular acoustical properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2471/00—Floor coverings
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F2290/00—Specially adapted covering, lining or flooring elements not otherwise provided for
    • E04F2290/04—Specially adapted covering, lining or flooring elements not otherwise provided for for insulation or surface protection, e.g. against noise, impact or fire
    • E04F2290/041—Specially adapted covering, lining or flooring elements not otherwise provided for for insulation or surface protection, e.g. against noise, impact or fire against noise

Definitions

  • the invention relates to the technical field of decorative panels, and in particular to a board, a soundproof floor and a manufacturing method thereof.
  • Chinese patent CN113802800A discloses a soundproof floor and a soundproof floor processing technology.
  • the soundproof floor includes a wear-resistant layer 100, a decorative layer 200, a substrate layer 300, a first soundproof layer 400 and a second soundproof layer 500 which are stacked in sequence.
  • Chinese patent CN115806713A discloses a floor with a sound-proof layer and a preparation method thereof.
  • the floor includes a floor layer and a sound-proof layer from top to bottom.
  • U.S. Patent US20220194068A1 discloses a laminate floor, as shown in Figure 5.
  • it includes a wear-resistant layer 1, a polyvinyl chloride patterned fabric layer 2, a substrate layer 3, a balancing layer 4 and a sound-proof layer 5 arranged in sequence. It can be seen that the sound-proof layer is arranged below the substrate layer, that is, on the side of the substrate layer facing away from the surface layer.
  • US Pat. No. 11619053B2 discloses a panel suitable for assembling waterproof floor or wall covering, as shown in FIG6 , comprising a rigid layer 12 and a core layer 10 disposed below the rigid layer 12 and substantially composed of a foam material.
  • the mute layer is disposed below the substrate layer, that is, located on the side of the substrate layer facing away from the surface layer.
  • Chinese patent CN218623044U discloses a glass fiber sound-absorbing board, as shown in FIG7 .
  • the board body 1 includes a base layer 11 and a surface layer 16 , and a moisture-proof layer 12 , a glass fiber felt 13 , a sound-absorbing layer 14 and a flame-retardant layer 15 are sequentially arranged between the base layer 11 and the surface layer 16 , that is, in this technical solution, the sound-absorbing layer 14 is arranged between the base layer 11 and the surface layer 16 , that is, it is located above the base layer 11 .
  • Chinese patent CN115262913A discloses a floor panel, as shown in FIG8 , in this technical solution, a layer capable of improving acoustic performance is provided between the core layer 202 and the decorative top layer 203.
  • the upper surface of the core layer 202 includes a plurality of cavities 206, which are configured in a predetermined pattern to scatter incoming sound waves.
  • providing cavities on the core layer, especially providing cavities on the upper surface of the core layer will undoubtedly reduce the acoustic performance of the core layer.
  • Structural strength on the one hand, the protrusions on both sides of the groove on the upper surface of the core layer will collapse; on the other hand, the softer sound-absorbing layer will easily affect the surface flatness of the floor due to uneven force on the bottom.
  • the substrate side is "closed".
  • the “unclosed side” of the substrate deforms more, while the “closed side” of the substrate deforms less, so the substrate will warp toward the "closed side”. This not only does not solve the problem of warping of the surface layer, but makes the overall warping problem of the board more serious.
  • a balancing layer is added to the lower side of the substrate, that is, the side away from the surface layer.
  • this can only suppress the warping of the substrate, and does not solve the warping problem of the decorative panel.
  • adhesive is used to bond the lower side of the substrate and the balancing layer.
  • the purpose of the present invention is to provide a board, a soundproof floor and a manufacturing method thereof.
  • a plate in a first aspect, includes a facing layer, a soundproofing cushion layer, and a glass magnesium layer stacked in sequence from top to bottom;
  • the glass magnesium layer is mainly formed by a composite of a substrate layer and a doping layer; the doping layer is located between the substrate layer and the mute pad layer, and the temperature and humidity deformation of the doping layer is greater than that of the substrate layer;
  • At least one second anti-stretching mesh layer is arranged in the doping layer, and meshes are arranged on the second anti-stretching mesh layer.
  • the doping layer materials on both sides of the second anti-stretching mesh layer form a connection structure through the meshes.
  • the thickness of the doping layer is greater than the thickness of the substrate layer, and the density of the substrate layer is higher than the density of the doping layer.
  • At least one first anti-stretching mesh layer is provided in the substrate layer, and a mesh is arranged on the first anti-stretching mesh layer.
  • the mesh is used to form a connection structure through the mesh of the materials forming the substrate layer on both sides of the first anti-stretching mesh layer.
  • the distance between the first anti-stretching mesh layer and the lower surface of the substrate layer is H 1 , and the value range of H 1 is 0.3-1.0 mm; the distance between the second anti-stretching mesh layer and the upper surface of the doping layer is H 2 , and the value range of H 2 is 1.5-3.0 mm;
  • the distance between the first anti-stretching mesh layer and the second anti-stretching mesh layer is greater than 4 mm.
  • the first anti-stretching mesh layer and the second anti-stretching mesh layer are neutral glass fiber mesh cloth or alkali-free glass fiber mesh cloth.
  • the neutral glass fiber mesh cloth or the alkali-free glass fiber mesh cloth has a gram weight greater than 100-200 g/m 2 .
  • a plate in a second aspect, includes a facing layer, a soundproofing cushion layer, and a glass magnesium layer stacked in sequence from top to bottom;
  • the glass magnesium layer is mainly formed by a composite of a substrate layer and a doping layer; the doping layer is located between the substrate layer and the mute pad layer, and the doping layer is mixed with lightweight fibers relative to the substrate layer, so that the density of the doping layer is less than that of the substrate layer;
  • At least one second anti-stretching mesh layer is arranged in the doping layer, and meshes are arranged on the second anti-stretching mesh layer.
  • the doping layer materials on both sides of the second anti-stretching mesh layer form a connection structure through the meshes.
  • the density of lightweight fibers such as wood flour, bamboo flour, straw flour, and rice husk flour is lower than the density of the material forming the base material layer.
  • the hardness of the doping layer is less than the hardness of the substrate layer.
  • the sound-proof cushion layer is EVA, and the EVA is subjected to double-sided corona treatment.
  • the EVA has a thickness of 1.0-1.5 mm and a Shore A hardness of 60-65.
  • the upper and lower surfaces of the soundproof cushion layer are respectively bonded to the finishing layer and the doping layer by polyurethane glue;
  • the coating amount of polyurethane adhesive is 100-110 g/m 2 .
  • the finishing layer includes melamine paper and density board stacked in sequence from top to bottom.
  • a soundproof floor comprises the board material in any one of the technical solutions in the first or second aspect
  • At least one side of the glass magnesium layer is provided with a connecting portion, and the other side opposite to the side is provided with a matching portion matched with the connecting portion.
  • the thickness of the glass magnesium layer is greater than 8 mm.
  • a method for making the soundproof floor as in the third aspect comprises the following steps:
  • pure slurry mixed with light fiber to form a glass magnesium board is added, and then the second anti-stretching mesh layer is laid, and then pure slurry mixed with filling fiber to form a glass magnesium board is added to cover the second anti-stretching mesh layer;
  • the plate After curing, the plate is processed to make it uniform in thickness;
  • a connecting portion is processed on at least one side of the glass magnesium layer, and a matching portion matched with the connecting portion is processed on the other side opposite to the side.
  • a board material comprises a veneer veneer and a glass magnesium layer stacked in sequence from top to bottom; wherein the glass magnesium layer is mainly formed by a composite of a substrate layer and a doping layer; the doping layer is located between the substrate layer and the soundproof cushion layer, and the temperature and humidity deformation of the doping layer is greater than the temperature and humidity deformation of the substrate layer; at least one second anti-stretching mesh layer is provided in the doping layer, and meshes are arranged on the second anti-stretching mesh layer, and the doping layer materials on both sides of the second anti-stretching mesh layer form a connection structure through the meshes.
  • the glass magnesium layer adopts the above-mentioned glass magnesium layer structure.
  • the density board of the present invention After the density board of the present invention is made into a thin decorative panel, it can withstand the impact of objects dropped from a height of 1 meter without being damaged, and can be used in most ground environments. At the same time, the thickness of the density board will not cause the product's silent effect to deteriorate.
  • corona-treated EVA is used as a silent cushion layer
  • polyurethane glue is used as an adhesive, which has good internal bonding strength.
  • the glass magnesium layer of the present invention includes a doping layer and a substrate layer stacked from top to bottom, and the substrate layer and the doping layer are respectively paved with a first anti-stretching mesh layer and a second anti-stretching mesh layer.
  • the product By controlling the second anti-stretching mesh layer in the doping layer to move toward the template surface during processing, that is, increasing the distance between the second anti-stretching mesh layer and the upper surface of the doping layer during processing, the product will produce warping at both ends toward the template surface, that is, downward warping, thereby reducing the warping problem caused by the decorative panel, thereby controlling the overall warping of the product.
  • FIG1 is a schematic diagram of the structure of a plate in one embodiment of the present invention.
  • FIG2 is a schematic diagram of the installation positions of the first anti-stretching mesh layer and the second anti-stretching mesh layer in one embodiment of the present invention
  • FIG3 is a schematic diagram of adjusting the warpage in one embodiment of the present invention.
  • FIG4 is a schematic diagram of the structure of a floor in the prior art
  • FIG5 is a schematic diagram of the structure of a floor in the prior art
  • FIG6 is a schematic diagram of the structure of a floor in the prior art
  • FIG7 is a schematic diagram of the structure of a floor in the prior art
  • FIG. 8 is a schematic structural diagram of a floor in the prior art.
  • 101 finishing layer
  • 102 Soundproof cushion
  • 103 doping layer
  • 104 second anti-stretching mesh layer
  • 105 substrate layer
  • 106 The first anti-stretching mesh layer.
  • the present application proposes a plate material, including a finishing layer 101 , a soundproofing cushion layer 102 , and a glass magnesium layer stacked in sequence from top to bottom.
  • the glass magnesium layer is mainly formed by a composite of a substrate layer 105 and a doping layer 103.
  • the doping layer 103 is located between the substrate layer 105 and the mute pad layer 102, and the temperature and humidity deformation of the doping layer 103 is greater than that of the substrate layer 105.
  • At least one second anti-stretching mesh layer 104 is provided in the doping layer 103, and meshes are arranged on the second anti-stretching mesh layer 104.
  • the doping layer 103 materials on both sides of the second anti-stretching mesh layer 104 form a connection structure through the meshes.
  • the glass magnesium layer is mainly formed by combining the substrate layer 105 and the doping layer 103.
  • the doping layer 103 is located between the substrate layer 105 and the mute pad layer 102, and the temperature and humidity deformation of the doping layer 103 is greater than that of the substrate layer 105.
  • the glass magnesium layer is a non-uniform and asymmetric structure formed by the substrate layer 105 and the doping layer 103.
  • the temperature and humidity deformation refers to the deformation amplitude of the substrate layer 105 and the doping layer 103 when the temperature changes, or the humidity changes, or both the temperature and humidity change under the same environmental conditions.
  • the deformation amplitude here refers to the amplitude of the warping at both ends of the plate.
  • the deformation amplitudes of the substrate layer 105 and the doping layer 103 are different.
  • the deformation of the substrate layer 105 is small, while the deformation of the doping layer 103 is large, thereby guiding the glass magnesium layer to warp downward, that is, to warp in the direction opposite to the warping direction of the finishing layer 101.
  • at least one second anti-stretching mesh layer 104 is provided in the doping layer.
  • a second anti-stretching mesh layer 104 is provided, and a mesh is arranged on the second anti-stretching mesh layer 104.
  • the mesh is used to form a connection structure through the mesh with the materials forming the doping layer on both sides of the second anti-stretching mesh layer 104.
  • the second anti-stretching mesh layer 104 can be made closer to the substrate layer 105, so that the upper part of the doping layer 104 is easier to deform, while the lower part thereof is less likely to deform, thereby guiding the glass magnesium layer to warp downward, thereby pulling the finishing layer 101, thereby reducing the amplitude of the upward warping of the finishing layer 101, thus solving the problem of pasting melamine on one side of a thin density board.
  • the board will have warping problems.
  • the present application proposes a plate material, comprising a finishing layer 101, a soundproofing cushion layer 102, and a glass magnesium layer stacked in sequence from top to bottom.
  • the glass magnesium layer is mainly formed by a composite of a substrate layer 105 and a doping layer 103.
  • the doping layer 103 is located between the substrate layer 105 and the mute pad layer 102, and the doping layer 103 is mixed with lightweight fibers relative to the substrate layer 105, so that the density of the doping layer 103 is less than that of the substrate layer 105.
  • At least one second anti-stretching mesh layer 104 is provided in the doping layer 103, and meshes are arranged on the second anti-stretching mesh layer 104, and the doping layer 103 materials on both sides of the second anti-stretching mesh layer 104 form a connection structure through the meshes.
  • the doping layer 103 When the doping layer 103 deforms more and the substrate layer 105 deforms less, the doping layer 103 will warp toward the side with less deformation, that is, the side of the substrate layer 105. At this time, the warping direction of the glass magnesium layer is opposite to the warping direction of the finishing layer 101, so that the whole board is balanced and the warping is smaller.
  • the facing layer 101 can be a wood cellulose facing, a paper layer, etc., or can be at least partially made of polyvinyl chloride, polyurethane, polypropylene, polyethylene terephthalate, chlorinated polyethylene, polyethylene, chlorinated PVC, acrylonitrile-butadiene-styrene, polycarbonate, etc.
  • the facing layer 101 includes melamine paper and density board stacked in sequence from top to bottom.
  • the melamine paper can be melamine colored paper, thereby enriching the decorativeness of the floor pattern, or can be melamine wear-resistant paper, thereby improving the wear resistance of the floor.
  • the thinner density board is used as a layer on the soundproof material to play a decorative role and also improve the durability of the product.
  • a thinner decorative panel may be used, such as a density board of 1 mm, so that the decorative panel can withstand the impact of objects dropped from a height of 1 meter without being damaged, and can be used in most ground environments.
  • a type of silent floor adopts a technical solution of setting a silent material under the glass magnesium layer.
  • the surface layer and the base material are impacted and generate noise, and the silent material under the base material isolates the sound generated by the impact from propagating downward.
  • the sound generated by the impact is not reduced.
  • Optimal sound attenuation is therefore achieved not by reducing the transmitted sound, but by reducing the sound that is generated, in particular when the floor surface is excited by an impact.
  • the amplitude and pitch of the sound produced is significantly reduced.
  • the mute pad 102 is disposed between the glass magnesium layer and the finishing layer 101, that is, the mute pad 102 is disposed above the glass magnesium layer.
  • the mute pad 102 absorbs the kinetic energy of the board being hit, thereby reducing the sound.
  • the mute function of this product is actually to offset the impact sound caused by people walking, stepping on, and dropping objects through the elasticity or resilience of the mute material.
  • the material of the soundproof cushion layer 102 can be EVA, IXPE, soundproof felt, non-woven fabric, flocking fabric, etc., or a foam material from PE, PS, PP, PU or melamine, or cork, etc.
  • EVA is used for the soundproofing cushion layer 102.
  • EVA has better soundproofing performance than IXPE of the same thickness, while soundproofing felt is more expensive and has a worse soundproofing effect than EVA, so EVA can be used for the soundproofing cushion layer 102.
  • the thickness of EVA is selected to be 1.0-1.5mm, preferably, it can be 1.2mm, 1.3mm, etc. In this product, the thickness of EVA is comprehensively considered by the product usage scenario and production cost.
  • the present embodiment since the present embodiment reduces the thickness of EVA, in order to make the sound-proof cushion layer 102 of the present embodiment still have better impact reduction performance after the pressure forming process, the present embodiment should not use EVA with lower hardness.
  • the Shore A hardness of EVA is 60-65, preferably, it can be 62, 64, etc. Low-hardness EVA is also prone to problems such as non-rebound (completely compressed) and large thickness deviation caused by inconsistent rebound during the pressurization process.
  • the thickness of EVA not too thick and the preferred EVA thickness is 1.0-1.5mm, and it is necessary to make the hardness of EVA not too low, and the preferred EVA hardness needs to meet the Shore A hardness of 60-65.
  • the plate made at this time will not have the problems of large thickness deviation and low surface flatness caused by the sound-proof material being too thick and the hardness being too low.
  • the adhesion between the sound-absorbing material and other layers is low.
  • the internal bonding strength between the sound-absorbing material and other layers is low, on the one hand, after long-term use, the bonding between the sound-absorbing cushion layer 102 and other layers is easy to break, resulting in bulging and edge warping.
  • the low internal bonding strength will make the finishing layer 101 unable to always be protected from Due to the tensile force of the glass magnesium layer, the plate will still have serious warping problems after a long time.
  • the sound-proof cushion layer 102 is EVA that has been subjected to double-sided corona treatment. After the EVA is subjected to corona treatment, abundant polar groups are given to the surface of the EVA, which is conducive to the attachment of foreign objects, thereby making the bonding strength of the EVA higher when it is bonded to other layers by glue.
  • the internal bonding strength of EVA treated with corona is higher than that of EVA not treated with corona.
  • the higher internal bonding strength allows the tension from the substrate layer to continue to act on the finishing layer 101. On the one hand, it can prevent the soundproofing pad 102 from being disconnected from the bonding with other layers after a long time.
  • maintaining a high internal bonding strength allows the finishing layer 101 to always be subjected to the tension from the glass magnesium layer, thereby reducing the warping of the board.
  • the upper and lower surfaces of the mute cushion layer are bonded to the finishing layer 102 and the doping layer 103 respectively by polyurethane glue, that is, EVA is bonded to the sanded surface of the density board and the doping layer respectively by polyurethane glue.
  • the sanded surface of the doping layer is chosen for bonding because the sanded surface is relatively rough, and the bonding strength between the sanded surface and the EVA is higher after the glue is applied.
  • polyurethane glue is more suitable for bonding EVA to the density board and the doping layer than other glues.
  • Taiwan Nanbao hot melt adhesive When using Taiwan Nanbao hot melt adhesive to bond EVA, after boiling for 3 hours, there is no adhesive layer peeling, and it can be torn off by hand after cooling.
  • the average internal bonding strength of the test is 0.37MPa, and the adhesive layer peels off. Comparing the test data of the above polyurethane adhesive bonding of non-corona EVA, it can be found that the internal bonding strength of EVA bonded by hot melt adhesive is much lower than that of EVA bonded by polyurethane adhesive.
  • the internal factor causing product warping is uneven stress distribution, which may be caused by moisture changes in the adhesive layer, temperature changes, insufficient adhesion, etc.
  • the amount of polyurethane adhesive applied is 100-110g/ m2 , thereby avoiding the warping problem caused by insufficient adhesion.
  • the material of the substrate is uniform and the structure is symmetrical.
  • this side of the substrate is "closed".
  • the board is deformed due to moisture absorption or other reasons, the "unclosed side” of the substrate deforms more greatly, while the "closed side” of the substrate deforms less.
  • the side with a larger deformation will warp toward the side with a smaller deformation, so the substrate will warp toward the "closed side”. This not only fails to solve the problem of the surface layer warping upward, but makes the problem of the overall upward warping of the board more serious.
  • the glass magnesium layer is a material with a uniform material and a symmetrical structure
  • the warping problem of the thin decorative panel cannot be reduced. This is also verified by trial production products, that is, when the glass magnesium layer is a material with a uniform and symmetrical structure, the product will have a serious upward warping problem.
  • a balancing layer needs to be added to the lower side of the substrate with uniform material, that is, the upper and lower surfaces of the substrate are sealed. On the one hand, this can only suppress the upward warping of the substrate, but does not solve the upward warping problem of the decorative panel.
  • the lower side of the substrate and the balancing layer are bonded with adhesive.
  • the plate includes a finishing layer 101, a soundproofing cushion layer 102, and a glass magnesium layer stacked in sequence from top to bottom.
  • the glass magnesium layer is mainly formed by a composite of a substrate layer 105 and a doping layer 103.
  • the doping layer 103 is located between the substrate layer 105 and the soundproofing cushion layer 102.
  • the temperature and humidity deformation of the doping layer 103 is greater than the temperature and humidity deformation of the substrate layer 105; in another embodiment, the density of the doping layer 103 is less than the density of the substrate layer 105.
  • the glass magnesium layer includes a substrate layer 105 and a doping layer 103 formed by filling light fibers in a material above the substrate layer 105 .
  • the substrate layer 105 and the doping layer 103 form an asymmetric structure.
  • the substrate layer 105 is made of a pure slurry for forming a glass magnesium board.
  • the thickness of the doping layer 103 is greater than the thickness of the substrate layer 105, thereby forming an asymmetric structure, and the hardness of the substrate layer 105 is greater than the hardness of the doping layer 103, and the density of the substrate layer 105 is better than the density of the doping layer 103, that is, the glass magnesium layer is a non-uniform structure.
  • the substrate layer 105 has a higher density, a higher hardness, slower water absorption, and less deformation.
  • the substrate layer 105 Since the substrate layer 105 has high density, high hardness, slow water absorption and small deformation, it is used as the lower layer. When the doping layer 103 is deformed due to water absorption or other reasons, its deformation is greater than that of the substrate layer 105. Therefore, the doping layer 103 will warp toward the side of the substrate layer 105 to form an "n"-shaped warp. Since the finishing layer 101 and the sound-absorbing pad layer 102 are bonded to the doping layer 103, the finishing layer 101 will be subjected to the tensile force from the doping layer 103. At this time, the "U"-shaped warping of the finishing layer 101 will be alleviated, thereby alleviating the overall warping of the board.
  • the substrate layer 105 Since the lower surface of the substrate layer 105 is the template surface, the template surface is smooth and fine, there is no wood fiber on the surface, and an obvious grid texture can be seen, which is the surface glass fiber mesh cloth. Since the lower surface of the substrate layer 105 is smooth and fine, the board looks good before paving, and it is not easy to produce chipping and powdering. In addition, the substrate layer 105 has good density, high hardness, slow water absorption, and has the advantage of being more durable, and is more suitable for being placed in the lower layer as the "outer layer".
  • the upper surface of the doping layer 103 is a sanded surface with obvious sanding marks, obvious wood fibers on the surface, and no grid texture.
  • the upper surface of the doping layer 103 is sanded by a sanding process to ensure the uniformity of thickness between batches of the substrate. After the substrate with uniform thickness is bonded to the soundproofing cushion layer 102 and the finishing layer 101, the overall flatness of the board is also high. Since about 0.5-1.0 mm of the doping layer 103 needs to be removed during the sanding process, the thicker doping layer 103 is more suitable to be placed in the upper layer, that is, on the side in contact with the soundproofing cushion layer 102.
  • the doping layer 103 is made by adding one or more light fiber powders such as wood powder, bamboo powder, straw powder, and husk powder to the pure material forming the glass magnesium board.
  • wood fiber powder can be added.
  • the density of light fiber powders such as wood powder, bamboo powder, straw powder, and husk powder is less than the density of the material forming the substrate layer.
  • the above-mentioned fiber powder can be doped only in the doping layer 103, while the substrate layer 105 is completely made of pure slurry for forming the glass magnesium board. It is also possible to choose to dope the above-mentioned fiber powder in the doping layer 103, while the substrate layer 105 is made by adding other powders to the pure slurry for forming the glass magnesium board. It is also possible to dope the above-mentioned fiber powder in both the doping layer 103 and the substrate layer 105, but the content of the fiber powder mixed in the substrate layer 105 is less, so that the glass magnesium layer is still a non-uniform and asymmetric structure.
  • At least one second anti-stretching mesh layer 104 is provided in the doping layer 103, such as one second anti-stretching mesh layer 104.
  • a mesh is arranged on the second anti-stretching mesh layer 104, and the mesh is used to form a connection structure through the mesh of the materials forming the doping layer on both sides of the second anti-stretching mesh layer 104.
  • the doping layer 103 is made by adding filling fibers to the pure material, the strength of the doping layer 103 is relatively low.
  • the second anti-stretching mesh layer 104 is provided in the doping layer 103.
  • the second anti-stretching mesh layer 104 can not only improve the strength of the doping layer 103, but also has an anti-stretching effect.
  • the position of the second anti-stretching mesh layer 104 can be closer to the substrate layer 105, the upper part of the doping layer 103 can be more easily deformed, and then the warping amplitude toward the lower side of the glass magnesium layer is larger, thereby achieving the effect of adjusting the overall warping of the board.
  • the adjustment direction is shown in Figure 3. Therefore, in this embodiment, the position of the second anti-stretching mesh layer 104 can be adjusted to offset the warping problem of the board caused by the thinner decorative panel.
  • At least one first anti-stretching mesh layer 106 is provided in the substrate layer 105, such as a first anti-stretching mesh layer 106.
  • the first anti-stretching mesh layer 106 is provided with meshes, and the meshes are used to form a connection structure through the meshes of the materials forming the substrate layer on both sides of the first anti-stretching mesh layer 106.
  • the strength can be higher and the deformation is less likely to be made, so that the upper part of the doping layer 104 is more likely to bend toward the substrate layer 105 after deformation. Qu means to bend downward.
  • the distance between the first anti-stretching mesh layer 106 and the lower surface of the substrate layer 105 is H1 , and the value range of H1 is 0.3-1.0 mm; the distance between the second anti-stretching mesh layer 104 and the upper surface of the doping layer 103 is H2 , and the value range of H2 is 1.5-3.0 mm. If the distance between the first anti-stretching mesh layer 106 and the lower surface of the substrate layer 105 is too small, and the distance between the second anti-stretching mesh layer 104 and the upper surface of the doping layer 103 is too small, the anti-stretching mesh layer may be exposed due to the falling of powder.
  • the thickness of the substrate layer 105 is 0.3-1.0 mm, and the thickness of the glass magnesium layer is greater than 8 mm.
  • the glass magnesium layer should not be too thin. If it is too thin, its strength is low. If the thickness of the substrate layer 105 is too large, due to its better density, greater hardness and smaller deformation, after the doping layer 103 warps toward the substrate layer 105, it is not easy to cause the glass magnesium layer to warp downward, and it is difficult to solve the warping problem of the finishing layer 101.
  • the first anti-stretching mesh layer 106 and the second anti-stretching mesh layer 104 are arranged in a flat manner, that is, when the glass magnesium layer is in the shape of a flat plate, the first anti-stretching mesh layer 106 and the second anti-stretching mesh layer 104 are laid on a plane formed by the length direction and the width direction of the flat plate, so that the first anti-stretching mesh layer 106 and the second anti-stretching mesh layer 104 are approximately perpendicular to the height direction of the flat plate.
  • the first anti-stretching mesh layer 106 and the second anti-stretching mesh layer 104 Due to the limitation of processing technology, it is difficult for the first anti-stretching mesh layer 106 and the second anti-stretching mesh layer 104 to be arranged in the glass magnesium layer in a completely flat posture. Therefore, the wavy curling of the first anti-stretching mesh layer 106 and the second anti-stretching mesh layer 104 within a slight range also belongs to the flat arrangement described in this embodiment.
  • first anti-stretching mesh layer 106 and the second anti-stretching mesh layer 104 have mesh holes connecting the upper and lower sides thereof, that is, the first anti-stretching mesh layer 106 and the second anti-stretching mesh layer 104 do not completely isolate the plate materials on the upper and lower sides thereof.
  • the slurry forming the plate materials on the upper and lower sides of the first anti-stretching mesh layer 106 and the second anti-stretching mesh layer 104 can be connected through the mesh holes provided in the first anti-stretching mesh layer 106 and the second anti-stretching mesh layer 104, thereby realizing that the first anti-stretching mesh layer 106 and the second anti-stretching mesh layer 104 are embedded in the plate materials in a grid-like manner.
  • the first anti-stretching mesh layer 106 and the second anti-stretching mesh layer 104 are both neutral glass fiber mesh cloth or alkali-free glass fiber mesh cloth, wherein the gram weight of the glass fiber mesh cloth is greater than 100-200g/ m2 .
  • the gram weight of the glass fiber mesh cloth is 150g/ m2 .
  • the mesh of the glass fiber mesh cloth can be 5*5mm or 4*4mm.
  • the mesh should not be too small. When the mesh is too small, the slurry on the upper and lower sides of the glass fiber mesh cloth may not be able to fill the mesh, thereby forming a cavity at the mesh. When the board is formed, it may collapse at the cavity, resulting in pits on the surface of the board.
  • the mesh should not be too large. Too large a mesh means that the filling density of the glass fiber mesh cloth is low, and the anti-stretching effect it provides is small, thereby affecting the mechanical properties and not conducive to reducing warping.
  • a board comprising a veneer veneer and a glass magnesium layer stacked in sequence from top to bottom.
  • the glass magnesium layer is mainly formed by a substrate layer and a doping layer.
  • the doping layer is located between the substrate layer and the mute pad layer.
  • the temperature and humidity deformation of the doping layer is greater than that of the substrate layer; at least one second anti-stretching mesh layer is provided in the doping layer, and meshes are arranged on the second anti-stretching mesh layer, and the doping layer materials on both sides of the second anti-stretching mesh layer form a connection structure through the meshes.
  • the glass magnesium layer of this embodiment can adopt the glass magnesium layer in the above embodiment.
  • the warping of the veneer veneer is different from that of the veneer panel mentioned in the above embodiment in that there is no obvious regularity in the warping direction of the veneer veneer, that is, it may warp upward or downward. Moreover, the warping problem of the veneer veneer is difficult to suppress.
  • a veneer veneer is provided on a single side of the glass magnesium layer, and the glass magnesium layer is mainly formed by a composite of a substrate layer and a doping layer.
  • the doping layer is located between the substrate layer and the soundproof cushion layer, and the temperature and humidity deformation of the doping layer is greater than that of the substrate layer.
  • the doping layer is warped toward the substrate layer, that is, warped downward, thereby guiding the veneer veneer to warp only downward. Under the premise that the warping of the veneer veneer cannot be suppressed, the veneer veneer is guided to warp only downward, thereby providing users with a better user experience.
  • the method for making the glass magnesium layer is: adding pure slurry to form a glass magnesium board on a pad, then laying a first anti-stretching mesh layer, and adjusting the sinking depth of the first anti-stretching mesh layer; then adding pure slurry to form a glass magnesium board mixed with lightweight fibers, and then laying a second anti-stretching mesh layer, and then adding pure slurry to form a glass magnesium board mixed with filling fibers to cover the second anti-stretching mesh layer.
  • pure material for forming the glass magnesium board is added to the pad, the first layer of glass fiber cloth is laid, the first layer of glass fiber cloth is sunk into the base material layer, and then pure material mixed with filling fiber, that is, the slurry of the doping layer is added, and then the second layer of glass fiber cloth is laid, and then pure material mixed with filling fiber is added, and then the exposed glass fiber cloth is cut, and then placed in a drying rack, cured at a temperature of 70-80 degrees Celsius for 2-3 days, and then transferred to room temperature curing for 7-10 days.
  • the template surface is polished, and finally the sanded surface is sanded through a sanding process to ensure the thickness uniformity between batches of the base material.
  • the product By controlling the second anti-stretching mesh layer 104 in the doping layer 103 to move toward the template surface during processing, that is, increasing the distance between the second anti-stretching mesh layer 104 and the upper surface of the doping layer 103 during processing, the product will produce warping at both ends toward the template surface, that is, "n"-shaped warping, thereby controlling the overall warping of the product and weakening the bending deformation caused by the thin decorative panel.
  • the lower surface of the glass magnesium layer may be provided with a wear-resistant sheet.
  • the glass magnesium layer and the wear-resistant sheet are bonded with PUR, and the PUR coating amount is 40-50g/ m2 .
  • a method for manufacturing a plate which mainly includes material preparation and structural assembly.
  • a layer of melamine paper needs to be laid on the upper surface of the 1mm density board, and then sent to a hot press to be hot pressed into a finishing layer; a five-layer hot press can be used, and during hot pressing, the pressure is 13-16MPa, the temperature is 135-145°C, and the time is 13-13.5 minutes.
  • the EVA coil or sheet is corona machined at a current of 0.5-1.0A and a speed of 10 m/s. Points, double-sided corona.
  • the sanded surface of the doping layer 103 is coated with adhesive at an ambient temperature below 25°C.
  • the adhesive is polyurethane adhesive, and the coating amount is 100-110 g/ m2 .
  • the coating amount is appropriate when there is slight adhesive overflow during pre-pressing.
  • the ambient temperature is controlled to be less than 25°C to prevent the adhesive from solidifying. If the adhesive or the rubber roller becomes sticky during the process, the rubber roller needs to be cleaned and replaced with new adhesive.
  • Attach the EVA with double-sided corona treatment on the adhesive surface roll it flat appropriately, add a pad for stacking, align the plates up and down when stacking, it is recommended that the stacking quantity is less than 30 sheets, and then add a cover plate for pre-pressing.
  • the pressure is 2-5MPa, and the pre-pressing time is not less than 40min.
  • the pressure is set at 2-5MPa to avoid the elastic structure of EVA being destroyed.
  • the products After re-pressing, the products are stacked individually and cured for 48 hours to allow the adhesive to fully cure.
  • a secondary gluing is performed, that is, the gluing machine is adjusted, the configured adhesive is applied, the adhesive is applied to the un-glued surface of the EVA at an ambient temperature below 25°C, and a finishing layer is attached, wherein the density board is in contact with the adhesive.
  • the adhesive is polyurethane adhesive, and the coating amount is 100-110g/ m2 .
  • the coating amount is appropriate to allow a slight overflow of adhesive during pre-pressing.
  • the ambient temperature should be controlled below 25°C to prevent the adhesive from solidifying. If the adhesive or the rubber roller becomes sticky during the process, the rubber roller needs to be cleaned and replaced with new glue.
  • each sheet needs to be stacked with a pad. When stacking, align the boards up and down. It is recommended that the stacking quantity is less than 30 sheets. Then add a cover plate for pre-compression.
  • the pressure is 2-5MPa, and the pre-pressing time is not less than 40 minutes.
  • the pre-pressing it is best to have a slight glue overflow around the board.
  • the re-pressing time is not less than 2 hours, and when the ambient temperature is not greater than 25°C, the re-pressing time is not less than 4 hours.
  • the pressure is set at 2-5MPa to avoid the elastic structure of EVA being destroyed.
  • the products After re-pressing, the products are stacked separately and cured for 48 hours to allow the adhesive to fully cure.
  • the warping test record of the board made of the facing layer 101, the mute cushion layer 102, and the glass magnesium layer stacked in sequence from top to bottom is as follows:
  • test records of the board made of the facing layer 101, the mute cushion layer 102, and the glass magnesium layer stacked in sequence from top to bottom are as follows:
  • a soundproof floor comprising the plate in the above embodiment, that is, in this embodiment, the soundproof floor is processed from the plate in the above embodiment.
  • at least one side of the glass magnesium layer is provided with a connecting portion, and the other side opposite to the side is provided with a matching portion adapted to the connecting portion.
  • a connecting portion when the plate is cut into a rectangular shape, a connecting portion can be processed at one long side of the glass magnesium layer, and a matching portion matched with the connecting portion can be processed at the other corresponding long side.
  • connection parts and matching parts here have been disclosed in the prior art.
  • the shapes thereof can adopt the connection parts and matching parts used in the floor in the prior art, and will not be described in detail here.
  • the glass magnesium layer needs to have a certain thickness to facilitate the processing of the connection part and the matching part, so as to achieve convenient installation.
  • the thickness of the glass magnesium layer is less than 8mm, when the adjacent silent floors are connected by matching the connection part and the matching part, the locking strength is weakened. Therefore, in this embodiment, the thickness of the glass magnesium layer is greater than 8mm.
  • the spacing between the first anti-stretching mesh layer 106 and the second anti-stretching mesh layer 104 is greater than 4mm.
  • a method for making a soundproof floor including material preparation, structural assembly, cutting and dividing, and grooving.
  • the method comprises the following steps: adding pure slurry for forming a glass magnesium board onto a backing plate, then laying a first anti-stretching mesh layer, and adjusting the sinking depth of the first anti-stretching mesh layer; then adding pure slurry for forming a glass magnesium board mixed with lightweight fibers, then laying a second anti-stretching mesh layer, and then adding pure slurry for forming a glass magnesium board mixed with filling fibers to cover the second anti-stretching mesh layer; after curing and solidification, processing the board to make its thickness uniform; bonding the facing layer to the soundproofing cushion layer, and bonding the soundproofing cushion layer to the glass magnesium layer; processing a connecting portion on at least one side of the glass magnesium layer, and processing a matching portion matched with the connecting portion on the other side opposite to the side.
  • a layer of melamine paper needs to be laid on the upper surface of the 1mm density board, and then sent to a hot press to be hot pressed into a finishing layer; a five-layer hot press can be used, and during hot pressing, the pressure is 13-16MPa, the temperature is 135-145°C, and the time is 13-13.5 minutes.
  • the EVA coil or sheet is subjected to double-sided corona treatment using a corona machine at a current of 0.5-1.0A and a speed of 10 m/min.
  • the product When the structure is assembled, the product includes, from top to bottom, a finishing layer 101, a glue layer, a soundproof cushion layer 102, a glue layer, and a glass magnesium layer.
  • the sanded surface of the doping layer is coated with adhesive at an ambient temperature below 25°C.
  • the adhesive is polyurethane adhesive, and the coating amount is 100-110g/ m2 .
  • the coating amount is appropriate when there is slight adhesive overflow during pre-pressing.
  • the ambient temperature is controlled to be less than 25°C to prevent the adhesive from solidifying. If the adhesive or the rubber roller becomes sticky during the process, the rubber roller needs to be cleaned and replaced with new adhesive.
  • Attach the EVA with double-sided corona treatment on the adhesive surface roll it flat appropriately, add a pad for stacking, align the plates up and down when stacking, it is recommended that the stacking quantity is less than 30 sheets, and then add a cover plate for pre-pressing.
  • the pressure is 2-5MPa, and the pre-pressing time is not less than 40min.
  • the pressure is set at 2-5MPa to avoid the elastic structure of EVA being destroyed.
  • the products After re-pressing, the products are stacked individually and cured for 48 hours to allow the adhesive to fully cure.
  • a secondary gluing is performed, that is, the gluing machine is adjusted, the configured adhesive is applied, the adhesive is applied to the un-glued surface of the EVA at an ambient temperature below 25°C, and a finishing layer is attached, wherein the density board is in contact with the adhesive.
  • the adhesive is polyurethane adhesive, and the coating amount is 100-110g/ m2 .
  • the coating amount is appropriate to allow a slight overflow of adhesive during pre-pressing.
  • the ambient temperature should be controlled below 25°C to prevent the adhesive from solidifying. If the adhesive or the rubber roller becomes sticky during the coating process, Clean the rubber roller and replace it with new rubber.
  • each board needs to be stacked with a pad.
  • the boards should be aligned up and down. It is recommended that the stacking quantity should be less than 30. Then add a cover board for pre-compression.
  • the pressure is 2-5MPa, and the pre-pressing time is not less than 40 minutes.
  • the pre-pressing it is best to have a slight glue overflow around the board.
  • the re-pressing time is not less than 2 hours, and when the ambient temperature is not greater than 25°C, the re-pressing time is not less than 4 hours.
  • the pressure is set at 2-5MPa to avoid the elastic structure of EVA being destroyed.
  • the products After re-pressing, the products are stacked separately and cured for 48 hours to allow the adhesive to fully cure.
  • the stacked small pieces of depanel are cured and the warpage and EVA rebound performance of the products are tested to ensure that the product thickness is uniform, there is no banana shape, and the warpage meets the requirements.
  • the grooves are cut according to the special mouth shape of the glass magnesium layer, and the connecting parts and matching parts are compared with the standard template to ensure that the gap, tightness, net size, etc. meet the requirements.
  • the process can be laid to check the assembly gap, assembly height difference, etc.
  • the warping degree of the soundproof floor manufactured in this embodiment meets the requirements.

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Abstract

本发明涉及装饰面板技术领域，具体涉及一种板材、静音地板及其制作方法，板材包括由上至下依次叠加的饰面层、静音垫层、玻镁层；该玻镁层主要由基材层和掺杂层复合形成；掺杂层内设有至少一层第二抗拉伸网层，第二抗拉伸网层上布设有网眼，第二抗拉伸网层两侧的掺杂层材料通过网眼形成连接结构。本发明的玻镁层包括由上至下叠加的掺杂层和基材层，基材层和掺杂层分别铺设有第一抗拉伸网层、第二抗拉伸网层，通过在加工时控制掺杂层中的第二抗拉伸网层往模板面移动，即在加工时增大第二抗拉伸网层距离掺杂层上表面的距离，从而产品会产生两端向模板面的翘曲，即向下翘曲，从而减弱饰面板引起的上翘问题，以此控制产品整体的翘曲。

Description

一种板材、静音地板及其制作方法 技术领域
本发明涉及装饰面板技术领域，具体涉及一种板材、静音地板及其制作方法。
背景技术
现如今，随着我国经济社会的不断发展以及人民生活水平的不断提高，人们改善居住环境的愿望愈加迫切，地板则是首选的装饰材料。人们对于地板的静音能力也是越来越在意。
中国专利CN113802800A公开了一种静音地板和静音地板加工工艺，如图4所示，在此技术方案中，静音地板包括依次层叠设置的耐磨层100、装饰层200、基材层300、第一静音层400和第二静音层500。
此外，又如中国专利CN115806713A公开了一种具有静音层的地板及其制备方法，在此技术方案中，地板从上至下依次包括地板层和静音层。
还如美国专利US20220194068A1公开了一种层压地板，如图5所示，在此技术方案中，包括依次排列的耐磨层1、聚氯乙烯图案织物层2、基材层3、平衡层4和静音层5，由此可知，其静音层均设于基材层的下方，即位于基材层背离面层的一侧。
同样地，在美国专利US11619053B2中公开了一种适用于组装防水地板或墙壁覆盖物的面板，如图6所示，包括刚性层12以及设于刚性层12下方，且基本由泡沫材料构成的芯层10。对于此技术方案，可以理解为静音层设于基材层的下方，即位于基材层背离面层的一侧。
对于上述这类静音地板，当鞋踩踏地板，或其他丢落物与这类静音板发生撞击时，面层和基材受到撞击而产生噪音，基材下方的静音材料则隔绝此撞击产生的声音向下传播(如楼下)。而对于静音板上方的空间而言(如安装此静音板的室内)，此撞击产生的声音并没有减小。即此类静音地板发挥的是“隔音”作用，而并非“消音”作用。
在另一类静音地板中，如中国专利CN218623044U公开了一种玻纤吸音板，如图7所示，在此技术方案中，板体1包括基层11与面层16，所述基层11与面层16之间依次设置有防潮层12、玻纤毡13、吸音层14与阻燃层15，即在此技术方案中，吸音层14是设于基层11和面层16之间的，即处于基层11上方。
此外，又如中国专利CN115262913A公开了一种地板镶板，如图8所示，在此技术方案中，位于芯层202与装饰性顶层203之间设有能够改善声学性能的层。另外，在此技术方案中，芯层202的上表面包括多个腔体206，这些腔体206以构造为散射传入声波的预定图案的方式存在。然而在芯层上设置空腔，尤其是在芯层的上表面设置空腔，无疑会降低芯层的 结构强度，一方面芯层的上表面凹槽两侧的凸起会塌陷，另一方面也会导致较软的静音层容易因底部受力不均而影响到地板的表面平整度。
对于将静音层设于基材层和面层之间的这一类静音地板，即将静音层设于基材层的上方，此种结构下，当均一的基材一侧贴附有静音层、面层时，基材这一侧形成“封闭”，当板材因吸湿或其他原因发生变形时，基材的“未封闭侧”变形较大，而基材的“封闭侧”变形较小，因此基材会朝“封闭侧”翘曲。这不仅没有解决面层翘曲的问题，反而会使得板材整体翘曲问题更为严重。现有技术中为了解决基材翘曲，会在基材的下侧，即背离面层的一侧加设平衡层，一方面，这只能抑制基材的上翘，并没有解决饰面板的上翘问题。另一方面，基材下侧与平衡层之间采用胶黏剂粘接。当使用胶黏剂粘接不同材质的两层材料时，使用何种胶黏剂能够确保两层材料始终保持良好结合强度也成为难题，即加设平衡层带来的材料选择、加工难度、生产成本等问题又成为行业所需解决的问题。
因此，如何提供一种可以有效解决地板翘曲，同时也能实现消音效果的地板结构，成为亟需解决的问题。
发明内容
为解决上述背景技术中提到的问题，本发明的目的是提供一种板材、静音地板及其制作方法。
本发明提供的技术方案为：
第一方面，一种板材，包括由上至下依次叠加的饰面层、静音垫层、玻镁层；
其中，该玻镁层主要由基材层和掺杂层复合形成；所述掺杂层位于基材层和静音垫层之间，且掺杂层的温湿形变度大于基材层的温湿形变度；
所述掺杂层内设有至少一层第二抗拉伸网层，第二抗拉伸网层上布设有网眼，第二抗拉伸网层两侧的掺杂层材料通过网眼形成连接结构。
作为第一方面一种可选的技术方案，所述掺杂层的厚度大于基材层的厚度，基材层的致密性高于掺杂层的致密性。
作为第一方面一种可选的技术方案，所述基材层中设有至少一层第一抗拉伸网层，第一抗拉伸网层上布设有网眼，此网眼用于使第一抗拉伸网层两侧形成基材层的材料通过网眼形成连接结构。
作为第一方面一种可选的技术方案，所述第一抗拉伸网层距基材层下表面的间距为H1，H1取值范围为0.3-1.0mm；所述第二抗拉伸网层距掺杂层上表面的间距为H2，H2取值范围为1.5-3.0mm；
第一抗拉伸网层和第二抗拉伸网层之间的间距大于4mm。
可选地，所述第一抗拉伸网层和第二抗拉伸网层为中性玻纤网格布或无碱玻纤网格布。
进一步地，中性玻纤网格布或无碱玻纤网格布的克重大于100-200g/m2。
第二方面，一种板材，包括由上至下依次叠加的饰面层、静音垫层、玻镁层；
其中，该玻镁层主要由基材层和掺杂层复合形成；所述掺杂层位于基材层和静音垫层之间，且掺杂层相对于基材层添加混合有轻质纤维，使得掺杂层的密度小于基材层的密度；
所述掺杂层内设有至少一层第二抗拉伸网层，第二抗拉伸网层上布设有网眼，第二抗拉伸网层两侧的掺杂层材料通过网眼形成连接结构。
作为第二方面一种可选的技术方案，所述掺杂层添加的轻质纤维包括木粉、竹粉、秸秆粉、谷壳粉中的一种或多种形成；
木粉、竹粉、秸秆粉、谷壳粉等轻质纤维的密度小于形成基材层的材料的密度。
作为第二方面一种可选的技术方案，所述掺杂层的硬度小于基材层的硬度。
作为第一或第二方面一种可选的技术方案，所述静音垫层为EVA，此EVA经过双面电晕处理。
作为第一或第二方面一种可选的技术方案，所述EVA的厚度为1.0-1.5mm，邵氏A硬度为60-65。
作为第一或第二方面一种可选的技术方案，静音垫层上下表面分别通过聚氨酯胶与饰面层、掺杂层粘接；
其中，聚氨酯胶涂布量为100-110g/m2。
作为第一或第二方面一种可选的技术方案，所述饰面层包括由上至下依次叠加的三聚氰胺纸和密度板。
第三方面，一种静音地板，包括第一或第二方面任意一种技术方案中的板材；
所述玻镁层至少一侧设有连接部，与该侧相对的另一侧设有与连接部相适配的配合部。
作为第三方面一种可选的技术方案，所述玻镁层的厚度大于8mm。
第四方面，一种如第三方面中静音地板的制作方法，包括以下步骤：
在垫板上加入形成玻镁板的纯浆料，然后铺入第一抗拉伸网层，调整第一抗拉伸网层沉入深度；
再加入混有轻质纤维的形成玻镁板的纯浆料，然后铺入第二抗拉伸网层，再加入混有填充纤维的形成玻镁板的纯浆料以覆盖第二抗拉伸网层；
养护固化后，加工板材使其厚度均匀；
将饰面层与静音垫层粘接，并将静音垫层与玻镁层粘接；
在玻镁层至少一侧加工出连接部，并在与该侧相对的另一侧加工出与连接部相适配的配合部。
第五方面，一种板材，包括由上至下依次叠加的木皮饰面和玻镁层；其中，该玻镁层主要由基材层和掺杂层复合形成；所述掺杂层位于基材层和静音垫层之间，且掺杂层的温湿形变度大于基材层的温湿形变度；所述掺杂层内设有至少一层第二抗拉伸网层，第二抗拉伸网层上布设有网眼，第二抗拉伸网层两侧的掺杂层材料通过网眼形成连接结构。玻镁层采用上述的玻镁层结构。
采用本发明提供的技术方案，与现有技术相比，具有如下有益效果：
本发明的密度板制成薄饰面板后，可以抵抗1米高度的丢落物的冲击而不破损，可适用于大部分地面环境使用，同时密度板的厚度也不会导致产品静音效果会变差。在本发明中，使用电晕处理的EVA作为静音垫层，同时使用聚氨酯胶作为胶黏剂，具备较好的内结合强度。本发明的玻镁层包括由上至下叠加的掺杂层和基材层，基材层和掺杂层分别铺设有第一抗拉伸网层、第二抗拉伸网层，通过在加工时控制掺杂层中的第二抗拉伸网层往模板面移动，即在加工时增大第二抗拉伸网层距离掺杂层上表面的距离，从而产品会产生两端向模板面的翘曲，即向下翘曲，从而减弱饰面板引起的上翘问题，以此控制产品整体的翘曲。
附图说明
图1为本发明一种实施例中板材的结构示意图；
图2为本发明一种实施例中第一抗拉伸网层和第二抗拉伸网层安装位置示意图；
图3为本发明一种实施例中调整翘曲时示意图；
图4为现有技术中一种地板的结构示意图；
图5为现有技术中一种地板的结构示意图；
图6为现有技术中一种地板的结构示意图；
图7为现有技术中一种地板的结构示意图；
图8为现有技术中一种地板的结构示意图。
示意图中的标号说明：
101：饰面层；
102：静音垫层；
103：掺杂层；
104：第二抗拉伸网层；
105：基材层；
106：第一抗拉伸网层。
具体实施方式
为进一步了解本发明的内容，结合附图和实施例对本发明作详细描述。
本说明书附图所绘示的结构、比例、大小等，均仅用以配合说明书所揭示的内容，以供熟悉此技术的人士了解与阅读，并非用以限定本发明可实施的限定条件，故不具技术上的实质意义，任何结构的修饰、比例关系的改变或大小的调整，在不影响本发明所能产生的功效及所能达成的目的下，均应仍落在本发明所揭示的技术内容得能涵盖的范围内。同时，本说明书中所引用的如“上”、“下”、“左”、“右”、“中间”等用语，亦仅为便于叙述的明了，而非用以限定可实施的范围，其相对关系的改变或调整，在无实质变更技术内容下，当亦视为本发明可实施的范畴。
在一种实施例中，如图1所示，本申请提出一种板材，包括由上至下依次叠加的饰面层101、静音垫层102、玻镁层。
其中，玻镁层主要由基材层105和掺杂层103复合形成。掺杂层103位于基材层105和静音垫层102之间，且掺杂层103的温湿形变度大于基材层105的温湿形变度。掺杂层103内设有至少一层第二抗拉伸网层104，第二抗拉伸网层104上布设有网眼，第二抗拉伸网层104两侧的掺杂层103材料通过网眼形成连接结构。
本实施例通过令玻镁层主要由基材层105和掺杂层103复合形成。掺杂层103位于基材层105和静音垫层102之间，且掺杂层103的温湿形变度大于基材层105的温湿形变度。从而令玻镁层为基材层105与掺杂层103形成的非均一且非对称结构。
其中，温湿度形变度是指在同一环境条件下，当温度变化时、或湿度变化时、或温度、湿度均变化时，基材层105和掺杂层103发生变形的幅度。当制成板材时，此处的变形幅度指的是板材两端翘曲的幅度。
基材层105和掺杂层103的变形幅度不同，基材层105的变形小，而掺杂层103的变形大，从而引导玻镁层向下翘曲，即与饰面层101翘曲方向相反的方向翘曲。并且在本实施例中，掺杂层内设有至少一层第二抗拉伸网层104，如设有一层第二抗拉伸网层104，第二抗拉伸网层104上布设有网眼，此网眼用于使第二抗拉伸网层104两侧形成掺杂层的材料通过网眼形成连接结构。本实施例可以通过令第二抗拉伸网层104更靠近基材层105，从而令掺杂层104的上部更容易变形，而其下部更不容易变形，从而引导玻镁层向下侧翘曲，从而牵拉饰面层101，从而降低饰面层101向上翘曲的幅度，这样解决在较薄的密度板单面贴三聚氰 胺纸时，板材会出现的翘曲问题。
在本发明的另一种实施例中，本申请提出一种板材，包括由上至下依次叠加的饰面层101、静音垫层102、玻镁层。
其中，玻镁层主要由基材层105和掺杂层103复合形成。掺杂层103位于基材层105和静音垫层102之间，且掺杂层103相对于基材层105添加混合有轻质纤维，使得掺杂层103的密度小于基材层105的密度。掺杂层103内设有至少一层第二抗拉伸网层104，第二抗拉伸网层104上布设有网眼，第二抗拉伸网层104两侧的掺杂层103材料通过网眼形成连接结构。
当掺杂层103变形较大而基材层105变形较小时，掺杂层103会朝向变形较小的那侧，即基材层105那侧翘曲，此时玻镁层翘曲方向与饰面层101翘曲方向相反，进而使得本板材整体达到平衡，翘曲较小。
在一种实施例中，饰面层101可以是木质纤维素饰面、纸层等，也可以是至少部分地由聚氯乙烯、聚氨酯、聚丙烯、聚对苯二甲酸乙二醇酯、氯化聚乙烯、聚乙烯、氯化PVC、丙烯腈-丁二烯-苯乙烯、聚碳酸酯等制成。
在一种实施例中，饰面层101包括由上至下依次叠加的三聚氰胺纸和密度板。
三聚氰胺纸可以是三聚氰胺彩纹纸，从而既丰富地板图案装饰性，也可以是三聚氰胺耐磨纸，从而提高地板的耐磨性能。
较薄的密度板作为静音材料上的一层，起到装饰作用，同时也可以提高产品耐用性。研究发现，产品在密度板单面贴三聚氰胺纸时，产品容易出现翘曲，后续裁切及服帖时难度大。而在密度板双面贴三聚氰胺纸时，虽然翘曲轻微，但制作工艺难度大。
此外，研究还发现密度板厚度增加，其静音效果会变差。但密度板过薄则易破损，且薄密度板易出现翘曲问题。
在一种实施例中，可以采用较薄的饰面板，如密度板可以是1mm，从而使得饰面板可以抵抗1米高度的丢落物的冲击而不破损，可适用于大部分地面环境使用。
现有技术中，一类静音地板采用的技术方案为在玻镁层的下方设置静音材料，对于这类静音地板，当鞋或其他丢落物与这类静音板发生撞击时，面层和基材受到撞击而产生噪音，基材下方的静音材料则隔绝此撞击产生的声音向下传播。而对于静音板上方的空间，如安装此静音板的室内而言，此撞击产生的声音并没有减小。
因此，最佳的声音衰减性能不是通过减小传输的声音来实现的，而是通过减小特别是在地板表面受到撞击激励时产生的声音来实现的。通过吸收和转换撞击的动能，能够实现所产 生的声音的振幅和音调的显著减小。
因此在本申请的一种实施例中，静音垫层102设于玻镁层与饰面层101之间，即静音垫层102设于玻镁层的上方，当踩踏此板材时，静音垫层102的作用是吸收板材受撞击的动能，从而减小声音。本产品具有的静音功能，其实是通过静音材料的弹性或回弹性，抵消人员走动、踩踏、丢落物引起的冲击声。
选择静音材料时，必须具有一定的回弹性、承重性。因此，静音垫层102的材料可以是EVA、IXPE、隔音毡、无纺布、植绒布等，也可以为来自PE、PS、PP、PU或三聚氰胺的泡沫材料，或者软木等。
在一种实施例中，静音垫层102选用EVA。同等厚度EVA隔音性能优于IXPE，隔音毡价格较高且静音效果不如EVA，所以静音垫层102可以选用EVA。
本行业中为使得静音材料能够更多地吸收静音板受撞击产生的动能，常见做法是采用更厚的静音材料，如2mm或大于2mm的静音材料。但由于本实施例的静音板在制作过程中存在加压成型工艺，此时较厚的EVA在加压过程中易出现不回弹(完全被压缩)、回弹不一致导致的厚度偏差大等问题，从而影响产品的开槽平整度和铺装平整度。因此本实施例中，EVA的厚度选为1.0-1.5mm，优选地，可以是1.2mm、1.3mm等，在本产品中，EVA的厚度由产品使用情景及生产成本综合考量。
由于本实施例降低了EVA厚度，为使得本实施例的静音垫层102在加压成型加工后仍能具备较优的降冲击性能，本实施例不宜采用较低硬度的EVA，在本实施例中，EVA的邵氏A硬度为60-65，优选地，可以是62、64等。低硬度的EVA在加压过程中同样易出现不回弹(完全被压缩)、回弹不一致导致的厚度偏差大等问题。因此本实施例中既需要令EVA的厚度不宜过厚，优选的EVA厚度为1.0-1.5mm，又需要令EVA的硬度不宜过低，优选的EVA硬度需满足邵氏A硬度为60-65。此时制成的板材，不会存在静音材料过厚、硬度过低导致的厚度偏差大、表面平整度不高的问题。
在现有技术中，一类静音板的静音材料与其他层的粘结力较低，以此实现后期对静音材料可更换的效果。如中国专利CN219753815U公开了一种易拼装可循环使用的静音弹性地板，在此技术方案中，其使用的厚质无纺布、植绒布等布类或植绒毛的表面黏胶量更少，从而后期拆卸循环使用更方便。
上述现有技术方案中，静音材料与其他层的粘接力较低，但是如果令静音材料与其他层的内结合强度较低，一方面在长时间使用后，静音垫层102与其他层粘接处易断开粘接，从而出现鼓包、边缘翘起现象。另一方面，低内结合强度会使得饰面层101无法始终受到来自 玻镁层的拉力作用，长时间后板材仍会存在较严重的翘曲问题。
在本申请一种实施例中，静音垫层102为经过双面电晕处理的EVA。EVA经电晕处理后，会赋予EVA表面丰富的极性基团，从而有利于附着外物，从而使得EVA通过胶水与其他层粘接时的粘接强度更高。
所以，经电晕处理的EVA较之不经电晕处理的EVA具有更高的内结合强度，具体试验记录如下表所示：
由此可知，经电晕处理的EVA相较于未经电晕处理的EVA，其内结合强度更高。较高的内结合强度，使得基材板层带来的拉力能够持续作用于饰面层101，一方面可以避免长时间后，静音垫层102与其他层粘接处断开粘接，另一方面，维持高内结合强度可以使得饰面层101始终能受到来自玻镁层的拉力作用，从而降低板材翘曲。
在一种实施例中，静音垫层上下表面分别通过聚氨酯胶与饰面层102、掺杂层103粘接，即EVA是通过聚氨酯胶分别与密度板、掺杂层的砂光面相粘接的。选择与掺杂层的砂光面粘接，是因为砂光面较为粗糙，涂胶后其与EVA的粘接强度更高。经研究发现，聚氨酯胶相较于其他胶，更适用于将EVA与密度板和掺杂层粘接。
当使用台湾南宝热熔胶粘接未电晕的EVA时，测试结果如下表所示：
当使用台湾南宝热熔胶粘接EVA时，水煮3小时后，无胶层剥离，冷却后手撕剥离。测试内结合强度平均为0.37MPa，胶层剥离。对比上述聚氨酯胶粘接未电晕的EVA测试数据可发现，热熔胶粘接EVA的内结合强度远低于聚氨酯胶粘接的EVA内结合强度。
引起产品翘曲的内在因素是应力分布不均，引起应力分布不均或变化的因素有可能是胶层的水分变化、温度变化、粘接力不足等。本实施例中，为保证EVA与密度板和掺杂层砂光面粘接力满足要求，聚氨酯胶涂布量为100-110g/m2，从而避免因粘接力不足导致的翘曲问题。
现有技术中，基材的材质均一且结构对称，当均一的基材一侧贴附有静音层、面层时，基材这一侧形成“封闭”，当板材因吸湿或其他原因发生变形时，基材的“未封闭侧”变形较大，而基材的“封闭侧”变形较小，变形较大一侧会向变形较小一侧翘曲，因此基材会朝“封闭侧”翘曲。这不仅没有解决面层向上翘曲的问题，反而会使得板材整体向上翘曲问题更为严重。所以，当玻镁层是材质均一且结构对称的材料时，就无法减轻薄饰面板的翘曲问题。通过试制产品也同样验证这一点，即玻镁层为结构均一且对称的材料时，产品会存在严重的向上翘曲问题。
目前现有技术中，为了解决这个问题需要在材质均一的基材的下侧加一层平衡层，即将基材上下两侧表面均封闭。一方面，这只能抑制基材的上翘，并没有解决饰面板的上翘问题。另一方面，基材下侧与平衡层之间采用胶黏剂粘接。当使用胶黏剂粘接不同材质的两层材料时，使用何种胶黏剂能够确保两层材料始终保持良好结合强度也成为难题。
在本申请的一种实施例中，板材包括由上至下依次叠加的饰面层101、静音垫层102、玻镁层。玻镁层主要由基材层105和掺杂层103复合形成。掺杂层103位于基材层105和静音垫层102之间。在一种实施方式中，掺杂层103的温湿形变度大于基材层105的温湿形变度；在另一种实施方式中，掺杂层103的密度小于基材层105的密度。
玻镁层包括基材层105以及在基材层105上方的材料中填充轻质纤维形成的掺杂层103，基材层105与掺杂层103形成非对称结构。
在一种实施例中，基材层105由形成玻镁板的纯浆料制成。
在一种实施例中，令掺杂层103的厚度大于基材层105的厚度，从而形成非对称结构，同时令基材层105的硬度大于掺杂层103的硬度，基材层105的致密性优于掺杂层103的致密性，即此时玻镁层为非均一结构。具体地，基材层105相较于掺杂层103，基材层105的致密性更高，硬度更高，吸水更慢，变形更小。
由于基材层105的致密性高、硬度高、吸水慢且变形小，所以将其作为下层，当掺杂层103因吸水或其他原因变形时，其变形大于基材层105，所以此时掺杂层103会朝向基材层105一侧翘曲，形成“n”形翘曲，由于饰面层101和静音垫层102与掺杂层103粘接，所以此时饰面层101会受到来自掺杂层103的拉力，则此时饰面层101的“U”形翘曲会得到缓解，从而板材整体翘曲情况得到缓解。
又由于基材层105的下表面为模板面，模板面平整细腻，表面无木纤维，可见明显的网格纹理，网格纹理为表层玻璃纤维网格布透出所现。由于基材层105下表面平整细腻，因此在铺装前，板材观感良好，且不易产生掉屑、掉粉现象。而且基材层105致密性好、硬度大，吸水慢，具有更耐用的优点，更适合放在下层作为“外层”使用。
掺杂层103的上表面为砂光面，砂光面有明显的砂光痕迹，表面有明显的木纤维存在，不见网格纹理。对掺杂层103的上表面通过砂光工艺进行砂光处理，保证了基材批次间的厚度均匀性，厚度均匀的基材在粘接静音垫层102和饰面层101之后，板材整体平整度也较高。由于砂光处理时需要去除约0.5-1.0mm的掺杂层103，因此较厚的掺杂层103更适合置于上层，即置于与静音垫层102接触的一侧。
在一种实施例中，掺杂层103是通过在形成玻镁板的纯料中添加木粉、竹粉、秸秆粉、谷壳粉中的一种或多种轻质纤维粉料制成。比如可以添加木纤维粉。木粉、竹粉、秸秆粉、谷壳粉等轻质纤维粉料的密度小于形成基材层的材料的密度。
应注意的是，可以仅在掺杂层103中掺杂上述纤维粉料，而基材层105完全是由形成玻镁板的纯浆料制成。也可以选择在掺杂层103中掺杂上述纤维粉料，而基材层105是由形成玻镁板的纯浆料中加入其他粉料制成。也可以是在掺杂层103和基材层105中均掺杂上述纤维粉料，只不过基材层105中混入的纤维粉料含量较少，使得玻镁层仍为非均一、非对称结构。
在一种实施例中，掺杂层103内设有至少一层第二抗拉伸网层104，如一层第二抗拉伸网层104。第二抗拉伸网层104上布设有网眼，此网眼用于使第二抗拉伸网层104两侧形成掺杂层的材料通过网眼形成连接结构。当在纯料中添加填充纤维制成掺杂层103时，掺杂层103的强度较低，为了增强其强度，在掺杂层103中设有第二抗拉伸网层104。
应注意的是，第二抗拉伸网层104不仅可以提高掺杂层103的强度，而且其本身具有抗拉伸作用，通过将第二抗拉伸网层104的位置调整至更靠近基材层105，可以使得掺杂层103的上部更易变形，进而朝玻镁层的下侧翘曲幅度更大，从而达到调整板材整体翘曲的效果，调整的方向如图3所示。所以在本实施例中，可以通过调整第二抗拉伸网层104的位置，来抵消较薄的饰面板引起的板材上翘问题。
在一种实施例中，基材层105中设有至少一层第一抗拉伸网层106，如一层第一抗拉伸网层106。第一抗拉伸网层106上布设有网眼，此网眼用于使第一抗拉伸网层106两侧形成基材层的材料通过网眼形成连接结构。通过在基材层105内设置第一抗拉伸网层106，可以使其强度更高，更不易变形，从而令掺杂层104的上部变形后更易朝向基材层105这一侧翘 曲，即下翘。
具体地，如图2所示，第一抗拉伸网层106距基材层105下表面的间距为H1，H1取值范围为0.3-1.0mm；第二抗拉伸网层104距掺杂层103上表面的间距为H2，H2取值范围为1.5-3.0mm。若第一抗拉伸网层106距基材层105下表面的间距过小、第二抗拉伸网层104距掺杂层103上表面的间距过小，则可能因粉料脱落导致抗拉伸网层裸露。
在本申请的一种实施例中，基材层105的厚度为0.3-1.0mm，且玻镁层的厚度大于8mm。玻镁层不宜过薄，如果过薄，则其强度较低。而基材层105的厚度如果过大，则由于其致密性更好、硬度更大、变形更小，则掺杂层103朝基材层105翘曲后，不易引起玻镁层向下翘曲，则难以解决饰面层101的上翘问题。
在本申请的一种实施例中，第一抗拉伸网层106和第二抗拉伸网层104为平铺式排布，即玻镁层为平板状时，第一抗拉伸网层106和第二抗拉伸网层104铺设在此平板的长度方向和宽度方向组成的平面上，从而令此第一抗拉伸网层106和第二抗拉伸网层104与此平板高度方向近似垂直。
受制于加工工艺的限制，第一抗拉伸网层106和第二抗拉伸网层104难以以完全平铺的姿态设于玻镁层中，因此第一抗拉伸网层106和第二抗拉伸网层104在轻微范围内产生波浪形卷曲也属于本实施例中描述的平铺式排布。
应注意的是，第一抗拉伸网层106和第二抗拉伸网层104是具有连通其上下两侧的网孔的，即第一抗拉伸网层106和第二抗拉伸网层104并非是将其上下两侧的板料完全隔绝的。制作玻镁层时，第一抗拉伸网层106、第二抗拉伸网层104上下两侧的形成板材的浆料是可以通过第一抗拉伸网层106和第二抗拉伸网层104设有的网孔连通的，由此以实现第一抗拉伸网层106和第二抗拉伸网层104是以网格状嵌入板材内部的。
在一种实施例中，第一抗拉伸网层106和第二抗拉伸网层104均为中性玻纤网格布或无碱玻纤网格布，其中，玻璃纤维网格布的克重大于100-200g/m2。比如玻璃纤维网格布的克重为150g/m2。玻璃纤维网格布的网眼可以为5*5mm，也可以是4*4mm。网眼不宜过小，当网眼过小时，玻璃纤维网格布上下侧的浆料会可能无法填充满网眼，从而在网眼处形成空洞，则当板材成型后，可能会在空洞处发生塌陷，从而造成板材表面形成坑洞。网眼也不宜过大，过大的网眼意味着玻璃纤维网格布的填充密度较低，其提供的抗拉伸作用较小，从而影响力学性能，不利于降低翘曲。
在本申请的一种实施例中，还提出一种板材，包括由上至下依次叠加的木皮饰面和玻镁层。其中，该玻镁层主要由基材层和掺杂层复合形成。掺杂层位于基材层和静音垫层之间， 且掺杂层的温湿形变度大于基材层的温湿形变度；掺杂层内设有至少一层第二抗拉伸网层，第二抗拉伸网层上布设有网眼，第二抗拉伸网层两侧的掺杂层材料通过网眼形成连接结构。本实施例的玻镁层可采用上述实施例中的玻镁层。
木皮饰面的翘曲情况与上述实施例中提到的饰面板不同之处在于，木皮饰面的翘曲方向无明显规律，即既会出现向上翘曲，也会出现向下翘曲的情况。而且，木皮饰面的翘曲问题很难抑制。
在本实施例中，在玻镁层的单面设置木皮饰面，并且此玻镁层主要由基材层和掺杂层复合形成。掺杂层位于基材层和静音垫层之间，且掺杂层的温湿形变度大于基材层的温湿形变度。本实施例中，由于掺杂层变形大于基材层，通过令掺杂层向基材层翘曲，即向下翘曲，从而引导木皮饰面也只向下翘曲。在无法抑制木皮饰面翘曲的前提下，通过引导木皮饰面只向下翘曲，从而给用户带来较好的使用体验。
在一种实施例中，玻镁层的制作方法为：在垫板上加入形成玻镁板的纯浆料，然后铺入第一抗拉伸网层，调整第一抗拉伸网层沉入深度；再加入混有轻质纤维的形成玻镁板的纯浆料，然后铺入第二抗拉伸网层，再加入混有填充纤维的形成玻镁板的纯浆料以覆盖第二抗拉伸网层。
具体地，在垫板上加入形成玻镁板的纯料，铺入第一层玻纤布，令第一层玻纤布下沉入基材层内部，然后加入混有填充纤维的纯料，即掺杂层的浆料，再铺入第二层玻纤布，再加入混有填充纤维的纯料，然后裁切露出的玻纤布，然后放入晾板架，在70-80摄氏度的温度下养护2-3天，再转由常温养护7-10天，确定长度和宽度后，对模板面抛光，最后对砂光面通过砂光工艺保证基材批次间的厚度均匀性。
通过在加工时控制掺杂层103中的第二抗拉伸网层104往模板面移动，即在加工时增大第二抗拉伸网层104距离掺杂层103上表面的距离，从而产品会产生两端向模板面的翘曲，即“n”形翘曲，以此控制产品整体的翘曲，从而连带减弱薄饰面板引起的弯曲变形。
作为一种可选的实施方式，玻镁层的下表面还可以设有耐磨片。玻镁层与耐磨片采用PUR粘接，PUR涂布量为40-50g/m2。
在本申请的一种实施例中，还提出一种板材的制作方法，主要包括材料准备、结构组胚。
具体地，准备饰面层101时，需要在1mm密度板上表面铺设一层三聚氰胺纸，再送入热压机热压成饰面层；可以采用五层热压机，热压时，压力为13-16MPa，温度是135-145℃，时间为13-13.5分钟。
准备静音垫层102时，将EVA卷材或片材用电晕机，以电流为0.5-1.0A、速度为10米/ 分，进行双面电晕。
准备胶黏剂时，选用聚氨酯双组份冷压胶，即组份A为树脂，组份B为固化剂，配比为A:B＝4:1。
结构组胚时，产品由上至下依次为饰面层101、胶层、静音垫层102、胶层、玻镁层。
具体地，在低于25℃的环境温度下对掺杂层103的砂光面涂胶黏剂，胶黏剂为聚氨酯胶，其涂布量为100-110g/m2。涂布量根据预压时有胶轻微溢出为宜。涂布过程控制环境温度小于25℃，防止胶黏剂固化，过程中若胶黏剂或胶辊起黏，需要清洗胶辊，换新配置胶。
在涂胶面贴附经双面电晕处理的EVA，可适当辊压压平，加垫板进行堆垛，堆垛时板材上下对齐，建议堆垛数量小于30张，再加盖板进行预压。预压时，压力为2-5MPa，且预压时间不小于40min。
然后再压，再压时，压力为2-5MPa，且当环境温度大于25℃时，再压时间不小于2小时，当环境温度不大于25℃时，再压时间不小于4小时。
令压力为2-5MPa，是为了避免EVA弹性结构被破坏。
再压后将产品单独码放，并养生48小时以令胶黏剂完全固化。
接下来进行二次涂胶，即调整涂胶机，上配置好的胶黏剂，在低于25℃的环境温度下对EVA的未施胶面涂胶黏剂，并贴附饰面层，其中，所述密度板与胶黏剂接触。
胶黏剂为聚氨酯胶，其涂布量为100-110g/m2。涂布量根据预压时有胶轻微溢出为宜。
涂布过程控制环境温度小于25℃，防止胶黏剂固化，过程中若胶黏剂或胶辊起黏，需要清洗胶辊，换新配置胶。
在涂胶表面，服帖饰面板，基材向下与涂胶面相合，因饰面板翘曲，所以每张需加垫板再堆垛，堆垛时板材上下对齐，建议堆垛数量小于30张。再加盖板进行预压。
预压时，压力为2-5MPa，且预压时间不小于40min。预压时，以板材四周轻微有胶溢出为宜。
再进行再压，再压时，压力为2-5MPa，且当环境温度大于25℃时，再压时间不小于2小时，当环境温度不大于25℃时，再压时间不小于4小时。
令压力为2-5MPa，是为了避免EVA弹性结构被破坏。
再压结束后将产品单独码放，并养生48小时以令胶黏剂完全固化。
根据上述制作方法试制产品后，对产品进行测试。
恒温恒湿箱温度50℃、湿度20％的环境下，以由上至下依次叠加的饰面层101、静音垫层102、玻镁层制成的板材翘曲测试记录如下：
在正常日晒条件下，记录产品每日上午八点和下午三点的翘曲度，以由上至下依次叠加的饰面层101、静音垫层102、玻镁层制成的板材测试记录如下：
由上表可知，以本实施例技术方案制得的板材，其翘曲度满足要求。
对板材施加三小时的1.5MPa压力后，对静音垫层102厚度回弹测试结果如下表所示：
在一种实施例中，还提出一种静音地板，包括上述实施例中的板材，即在此实施例中，静音地板是由上述实施例中的板材加工而成。具体地，玻镁层至少一侧设有连接部，与该侧相对的另一侧设有与连接部相适配的配合部。
在一种实施例中，当板材被裁切成长方形状时，可以在玻镁层的一条长边处加工出连接部，而在相对应的另一条长边处加工出与连接部相适配的配合部。
这里的连接部和配合部在现有技术中已披露较多，其形状可以采用现有技术中地板使用的连接部和配合部造型，在此不再赘述。
应注意的是，玻镁层需具有一定的厚度，便于加工连接部和配合部，从而实现便捷安装。当玻镁层厚度小于8mm时，当相邻静音地板通过连接部和配合部相适配实现连接时，其锁扣强度减弱。所以在本实施例中，玻镁层的厚度大于8mm。
同样需要注意的是，为解决在薄密度板单面贴三聚氰胺纸时，产品会出现的翘曲问题，当玻镁层的厚度大于8mm时，第一抗拉伸网层106和第二抗拉伸网层104之间的间距大于 4mm。
在一种实施例中，还提出一种静音地板的制作方法，包括材料准备、结构组胚、裁切与分板、开槽。
具体地，包括以下步骤：在垫板上加入形成玻镁板的纯浆料，然后铺入第一抗拉伸网层，调整第一抗拉伸网层沉入深度；再加入混有轻质纤维的形成玻镁板的纯浆料，然后铺入第二抗拉伸网层，再加入混有填充纤维的形成玻镁板的纯浆料以覆盖第二抗拉伸网层；养护固化后，加工板材使其厚度均匀；将饰面层与静音垫层粘接，并将静音垫层与玻镁层粘接；在玻镁层至少一侧加工出连接部，并在与该侧相对的另一侧加工出与连接部相适配的配合部。
具体地，准备饰面层101时，需要在1mm密度板上表面铺设一层三聚氰胺纸，再送入热压机热压成饰面层；可以采用五层热压机，热压时，压力为13-16MPa，温度是135-145℃，时间为13-13.5分钟。
准备静音垫层102时，将EVA卷材或片材用电晕机，以电流为0.5-1.0A、速度为10米/分，进行双面电晕。
准备胶黏剂时，选用聚氨酯双组份冷压胶，即组份A为树脂，组份B为固化剂，配比为A:B＝4:1。
结构组胚时，产品由上至下依次为饰面层101、胶层、静音垫层102、胶层、玻镁层。
具体地，在低于25℃的环境温度下对掺杂层的砂光面涂胶黏剂，胶黏剂为聚氨酯胶，其涂布量为100-110g/m2。涂布量根据预压时有胶轻微溢出为宜。涂布过程控制环境温度小于25℃，防止胶黏剂固化，过程中若胶黏剂或胶辊起黏，需要清洗胶辊，换新配置胶。
在涂胶面贴附经双面电晕处理的EVA，可适当辊压压平，加垫板进行堆垛，堆垛时板材上下对齐，建议堆垛数量小于30张，再加盖板进行预压。预压时，压力为2-5MPa，且预压时间不小于40min。
然后再压，再压时，压力为2-5MPa，且当环境温度大于25℃时，再压时间不小于2小时，当环境温度不大于25℃时，再压时间不小于4小时。
令压力为2-5MPa，是为了避免EVA弹性结构被破坏。
再压后将产品单独码放，并养生48小时以令胶黏剂完全固化。
接下来进行二次涂胶，即调整涂胶机，上配置好的胶黏剂，在低于25℃的环境温度下对EVA的未施胶面涂胶黏剂，并贴附饰面层，其中，所述密度板与胶黏剂接触。
胶黏剂为聚氨酯胶，其涂布量为100-110g/m2。涂布量根据预压时有胶轻微溢出为宜。
涂布过程控制环境温度小于25℃，防止胶黏剂固化，过程中若胶黏剂或胶辊起黏，需要 清洗胶辊，换新配置胶。
在涂胶表面，服帖饰面板，基材向下与涂胶面相合，因饰面板翘曲，所以每张需加垫板再堆垛，堆垛时板材上下对齐，建议堆垛数量小于30张。再加盖板进行预压。
预压时，压力为2-5MPa，且预压时间不小于40min。预压时，以板材四周轻微有胶溢出为宜。
再进行再压，再压时，压力为2-5MPa，且当环境温度大于25℃时，再压时间不小于2小时，当环境温度不大于25℃时，再压时间不小于4小时。
令压力为2-5MPa，是为了避免EVA弹性结构被破坏。
再压结束后将产品单独码放，并养生48小时以令胶黏剂完全固化。
对产品进行裁切与分板时，根据出材率最大化原则进行裁切与分板，先短边两端铣边，作为基准边，再长边分板，区分摆放方向，通透式堆垛，堆垛高度建议小于1米。
分板已堆垛的小片进行养生出来，检测产品的翘曲度与EVA回弹性能，确保产品厚度均匀，无香蕉型，且翘曲度满足要求。
开槽时，根据玻镁层专用口型进行开槽，连接部、配合部与标准模板进行对比，确保间隙、松紧度、净尺寸等满足要求，过程可铺装查看拼装离缝、拼装高低差等。
开槽后，随机抽取6片产品检测翘曲度，以由上至下依次叠加的饰面层101、静音垫层102、玻镁层制成的静音地板检测结果如下表所示：
由此可见，本实施例制成的静音地板翘曲度满足要求。
以上示意性的对本发明及其实施方式进行了描述，该描述没有限制性，附图中所示的也只是本发明的实施方式之一，实际的结构并不局限于此。所以，如果本领域的普通技术人员受其启示，在不脱离本发明创造宗旨的情况下，不经创造性的设计出与该技术方案相似的结构方式及实施例，均应属于本发明的保护范围。

Claims (17)

  1. 一种板材，其特征在于：包括由上至下依次叠加的饰面层、静音垫层、玻镁层；
    其中，该玻镁层主要由基材层和掺杂层复合形成；所述掺杂层位于基材层和静音垫层之间，且掺杂层的温湿形变度大于基材层的温湿形变度；
    所述掺杂层内设有至少一层第二抗拉伸网层，第二抗拉伸网层上布设有网眼，第二抗拉伸网层两侧的掺杂层材料通过网眼形成连接结构。
  2. 根据权利要求1所述的板材，其特征在于：所述掺杂层的厚度大于基材层的厚度，基材层的致密性高于掺杂层的致密性。
  3. 根据权利要求2所述的板材，其特征在于：所述基材层中设有至少一层第一抗拉伸网层，第一抗拉伸网层上布设有网眼，此网眼用于使第一抗拉伸网层两侧形成基材层的材料通过网眼形成连接结构。
  4. 根据权利要求3所述的板材，其特征在于：
    所述第一抗拉伸网层距基材层下表面的间距为H1，H1取值范围为0.3-1.0mm；
    所述第二抗拉伸网层距掺杂层上表面的间距为H2，H2取值范围为1.5-3.0mm；
    第一抗拉伸网层和第二抗拉伸网层之间的间距大于4mm。
  5. 根据权利要求3所述的板材，其特征在于：所述第一抗拉伸网层和第二抗拉伸网层为中性玻纤网格布或无碱玻纤网格布。
  6. 根据权利要求5所述的板材，其特征在于：中性玻纤网格布或无碱玻纤网格布的克重大于100-200g/m2。
  7. 一种板材，其特征在于：包括由上至下依次叠加的饰面层、静音垫层、玻镁层；
    其中，该玻镁层主要由基材层和掺杂层复合形成；所述掺杂层位于基材层和静音垫层之间，且掺杂层相对于基材层添加混合有轻质纤维，使得掺杂层的密度小于基材层的密度；
    所述掺杂层内设有至少一层第二抗拉伸网层，第二抗拉伸网层上布设有网眼，第二抗拉伸网层两侧的掺杂层材料通过网眼形成连接结构。
  8. 根据权利要求7所述的板材，其特征在于：所述掺杂层添加的轻质纤维包括木粉、竹粉、秸秆粉、谷壳粉中的一种或多种；
    所述轻质纤维的密度小于形成基材层的材料的密度。
  9. 根据权利要求7所述的板材，其特征在于：所述掺杂层的硬度小于基材层的硬度。
  10. 根据权利要求1-9中任意一项所述的板材，其特征在于：所述静音垫层为EVA，此EVA经过双面电晕处理。
  11. 根据权利要求10所述的板材，其特征在于：所述EVA的厚度为1.0-1.5mm，邵氏A 硬度为60-65。
  12. 根据权利要求10所述的板材，其特征在于：静音垫层上下表面分别通过聚氨酯胶与饰面层、掺杂层粘接；
    其中，聚氨酯胶涂布量为100-110g/m2。
  13. 根据权利要求1-9中任意一项所述的板材，其特征在于：所述饰面层包括由上至下依次叠加的三聚氰胺纸和密度板；所述玻镁层的厚度大于8mm。。
  14. 一种板材，其特征在于：包括由上至下依次叠加的木皮饰面和玻镁层；
    其中，该玻镁层主要由基材层和掺杂层复合形成；所述掺杂层位于基材层和静音垫层之间，且掺杂层的温湿形变度大于基材层的温湿形变度；
    所述掺杂层内设有至少一层第二抗拉伸网层，第二抗拉伸网层上布设有网眼，第二抗拉伸网层两侧的掺杂层材料通过网眼形成连接结构。
  15. 根据权利要求14所述的一种板材，其特征在于，所述玻镁层采用权利要求2～13中任一项所述的玻镁层结构。
  16. 一种静音地板，其特征在于，包括如权利要求1-13中任意一项所述的板材；
    所述玻镁层至少一侧设有连接部，与该侧相对的另一侧设有与连接部相适配的配合部。
  17. 一种如权利要求16所述的静音地板的制作方法，其特征在于，包括以下步骤：
    在垫板上加入形成玻镁板的纯浆料，然后铺入第一抗拉伸网层，调整第一抗拉伸网层沉入深度；
    再加入混有轻质纤维的形成玻镁板的纯浆料，然后铺入第二抗拉伸网层，再加入混有填充纤维的形成玻镁板的纯浆料以覆盖第二抗拉伸网层；
    养护固化后，加工板材使其厚度均匀；
    将饰面层与静音垫层粘接，并将静音垫层与玻镁层粘接；
    在玻镁层至少一侧加工出连接部，并在与该侧相对的另一侧加工出与连接部相适配的配合部。
PCT/CN2024/097971 2023-12-04 2024-06-07 一种板材、静音地板及其制作方法 Pending WO2025118518A1 (zh)

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