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CN105873761A - 具有表面层的基于木纤维的板 - Google Patents

具有表面层的基于木纤维的板 Download PDF

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Publication number
CN105873761A
CN105873761A CN201580003660.8A CN201580003660A CN105873761A CN 105873761 A CN105873761 A CN 105873761A CN 201580003660 A CN201580003660 A CN 201580003660A CN 105873761 A CN105873761 A CN 105873761A
Authority
CN
China
Prior art keywords
subgrade
veneer
surface layer
wood fiber
layer
Prior art date
Legal status (The legal status 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 status listed.)
Pending
Application number
CN201580003660.8A
Other languages
English (en)
Inventor
G·齐格勒
D·佩尔万
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Valinge Innovation AB
Original Assignee
Valinge Innovation AB
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 Valinge Innovation AB filed Critical Valinge Innovation AB
Priority to CN201911148535.2A priority Critical patent/CN110861373A/zh
Publication of CN105873761A publication Critical patent/CN105873761A/zh
Pending legal-status Critical Current

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Classifications

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Landscapes

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  • Manufacturing & Machinery (AREA)
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  • Physics & Mathematics (AREA)
  • Mechanical Engineering (AREA)
  • Laminated Bodies (AREA)
  • Chemical And Physical Treatments For Wood And The Like (AREA)
  • Finished Plywoods (AREA)
  • Floor Finish (AREA)
  • Veneer Processing And Manufacture Of Plywood (AREA)
  • Panels For Use In Building Construction (AREA)
  • Dry Formation Of Fiberboard And The Like (AREA)
  • Application Of Or Painting With Fluid Materials (AREA)
  • Finishing Walls (AREA)

Abstract

建筑板具有含木单板的表面层(1)、基于木纤维的芯层(2)和在表面层(1)与芯层(2)之间的亚层(3)。亚层(3)包含木纤维(4)和粘合剂(5)。表面层(1)具有包含来自亚层(3)的材料的表面部分(6)。包含来自亚层(3)的材料的表面部分(6)延伸到木单板中。

Description

具有表面层的基于木纤维的板
技术领域
本公开大体上涉及但不限于具有表面层的基于木纤维的建筑板，优选地板、墙板和家具部件的领域。
技术背景
本发明的实施方案特别适用于由具有木纤维芯层和装饰性耐磨表面的地板形成的浮动地板。下列已知技术描述、已知系统的问题和本公开的目的和特征因此，作为非限制性实例，尤其针对这一应用领域，特别针对类似于传统的基于木纤维的层压地板的地板。
应该强调，本发明的实施方案也可用于其它用途，例如墙板、天花板、家具部件和类似物。
已知技术及其问题
使用几种技术提供作为实木地板的复制品的地板。其原因在于可以更成本有效地制造复制品并且具有粘贴到例如HDF或胶合板的芯层上的单独层的地板比实木地板更耐湿。
基于木纤维的直接压贴(direct pressed laminated)地板通常包含由6-12毫米纤维板构成的芯层、0.2毫米厚的由层压材料构成的上装饰表面层和0.1-0.2毫米厚的由层压材料、塑料、纸或类似材料构成的下平衡层。
层压表面通常包含两个纸片——0.1毫米厚的印刷装饰纸和旨在防止该装饰纸磨损的透明0.05-0.1毫米厚的贴面。由α-纤维素纤维制成的透明贴面包含小的硬质和透明的氧化铝粒子，其赋予该表面层高耐磨性。
该印刷装饰纸和贴面用蜜胺树脂浸渍并在热和压力下层压到基于木纤维的芯层上。这两张纸在压制前具有大约0.3毫米的总厚度，且它们在压制后压缩到大约0.2毫米。
其它常见表面材料是胶合到芯层上的木单板(veneer)和箔。该表面也可以是包含木纤维、蜜胺树脂、有色颜料和氧化铝粒子的粉末层。
木单板可提供最天然的复制品。缺点在于木单板通常具有比层压地板低的抗冲击性并在使用优质单板时生产成本高。
已知可以将木单板压制在如上所述的粉末层上且这种粉末层可提供提高的抗冲击性。这并未解决成本问题。
US 2,831,793公开了复合木单板。将薄单板施加到木素纤维粒子和粘合剂的复合纤维芯层上并在一起压制以形成复合板时用芯层材料填充该单板的开孔。在根据此文献的胶合板或贴面板的制造中，与板的形成同时进行表面层开孔缺陷的封堵。
概述
本发明的至少某些实施方案的目的是提供具有基于木的表面层的建筑板，如地板，其与目前已知的地板相比具有更有吸引力的表面设计和/或更好的表面性质和/或成本结构。
通过一种建筑板实现从该说明书中显而易见的这些和其它目的和优点的至少一些，所述建筑板包含含木单板的表面层、基于木纤维的芯层和布置在表面层与基于木纤维的芯层之间的亚层。该亚层包含木纤维和粘合剂。该表面层具有包含来自亚层的材料的表面部分。包含来自亚层的材料的表面部分可延伸到木单板中。
“延伸到木单板中”是指来自亚层的材料例如至少延伸到木单板厚度的1/3中。在一个实施方案中，亚层的材料完全贯穿木单板。
该表面部分可延伸到表面层的上部。
包含来自亚层的材料的表面部分可以与表面层的其余部分齐平。
在一个实施方案中，该芯层可以是基于木的板，例如基于木纤维的板，如MDF或HDF，或胶合板。该芯层可以是木塑复合材料(Wood PlasticComposite，WPC)。在一个实施方案中，该芯层可以是矿物复合板、纤维水泥板、氧化镁水泥板、陶瓷板或塑料板，如热塑性塑料板。
该芯层优选是预制芯层。
在一个实施方案中，该单板层可以是木单板、软木单板或石单板(stoneveneer)。
在一个实施方案中，该亚层可包含填料和粘合剂。该填料可以是粒子或纤维，例如木纤维或粒子，或矿物粒子或纤维。该木粒子可以是木素纤维粒子和/或纤维素粒子。该木粒子可以至少部分漂白。该填料可以是稻米、秸秆、玉米、黄麻、亚麻、胡麻、棉、大麻、竹、甘蔗渣或剑麻粒子或纤维。该填料可以是淀粉，如玉米淀粉、马铃薯淀粉等。
该单板的厚度可以为大约0.2毫米至大约1毫米。
与具有单板的已知建筑板相比，可以为建筑板提供更薄单板，因为亚层加强该单板。
可以为建筑板提供包含穿过单板的孔隙，如裂纹的部分破裂单板。该亚层可穿过孔隙伸出并与表面层齐平。该亚层可作为油灰的替代物用于具有破裂表面层的建筑板。来自亚层的材料可填充该单板的孔隙，如裂纹。
该单板在压制前也可以预处理，例如刷处理。
表面层可包含压花部分且一部分亚层可能在压花部分下比在非压花表面部分下被更多地压缩。
压花部分可以在压制后天然存在。对于具有多孔结构的木单板，如硬木(例如被子植物)，该单板的多孔部分在压制后形成压花部分，因为这些部分在释放压力时不会从它们的压缩状态回弹。这些多孔部分在压制过程中被亚层的粘合剂填充。然后该粘合剂固化和/或硬化，该粘合剂将多孔部分的位置锁定在压缩状态下。具有高密度，即无孔的单板部分在压制过程中压缩但在释放压力时回弹，由此形成表面层的突起。高密度部分未从亚层中吸收足够的粘合剂以致无法在压制后被硬化粘合剂锁定。
对于具有无孔结构的木单板，如软木(例如裸子植物)，具有高密度的夏材年轮(也称作晚材年轮)在压制过程中不可压缩。相反，夏材年轮被压入亚层中以压缩亚层。夏材年轮形成该表面层的压花部分。春材年轮(也称作早材年轮)在压制过程中可压缩。在压制过程中，春材年轮被压缩。然后释放压力，春材年轮回弹并形成突起。
也可通过用压花压制装置，如压花压板压制形成该表面层的压花部分。
该建筑板可包含基于粉末的平衡层。该基于粉末的平衡层可包含纤维素或木素纤维粒子和粘合剂。在一个实施方案中，该建筑板包含含有优选被热固性粘合剂浸渍的树脂浸渍纸的平衡层。
该建筑板可以是包含基于粉末的平衡层的地板。该基于粉末的平衡层可包含纤维素或木素纤维粒子和粘合剂。在一个实施方案中，该地板包含含有优选被热固性粘合剂浸渍的树脂浸渍纸的平衡层。
亚层中的粘合剂可以是热固性树脂。
亚层中的粘合剂可以是蜜胺树脂。亚层中的粘合剂可以是氨基树脂，如三聚氰胺甲醛树脂、脲醛树脂、酚醛树脂或其组合。
亚层中的粘合剂可以是热塑性粘合剂。该热塑性粘合剂可以是聚氯乙烯(PVC)、聚乙烯(PE)、聚丙烯(PP)、聚氨酯(PU)、聚乙烯醇(PVOH)、聚乙烯醇缩丁醛(PVB)和/或聚乙酸乙烯酯(PVAc)或其组合。
该粘合剂可以是木材胶粘剂(wood mastic)、木材填料或任何其它类型的类似油灰的糊剂。
亚层可以基本或完全无甲醛。
亚层中的木纤维可以是木素纤维和/或纤维素粒子。该木纤维可以至少部分漂白。
亚层可包含耐磨粒子。
亚层可进一步包含有色颜料和/或着色剂。该有色颜料可以为黑色或可以为白色，如TiO2。
该木单板可包含孔隙和/或裂纹，其中亚层填充该木单板的孔隙和/或裂纹。
表面层可进一步包含布置在木单板上的包含耐磨粒子的保护贴面。
亚层可包含起泡剂。在亚层中可包括添加剂，如发泡剂。该发泡剂可以是物理发泡剂，如和/或化学起泡剂，如AIBN(偶氮异丁腈)或ADC(偶氮二甲酰胺)。
该表面层可以是软木层。
该建筑板可以是地板、墙板、天花板、家具部件、踢脚板、模制品、镶边型材等。
该单板的替代品可以是带有贯穿纸或塑料箔的孔的纸或塑料箔。
本发明的第二方面是一种制造建筑板的方法，其包含以下步骤：
·在基于木纤维的芯层上施加木纤维粉末和粘合剂，以获得亚层；
·在所述亚层上施加木单板，其包含穿过所述单板的孔隙，
·施加热和压力以将所述单板、所述亚层和所述基于木纤维的芯层粘合在一起，其中一部分木纤维粉末和粘合剂被压入所述孔隙中。
该方法优选包括施加起泡剂的步骤。起泡剂可促进木纤维粉末和试剂移动到孔隙中。
该木纤维粉末可包含木素纤维粒子或纤维素粒子。
该方法可包括施加不同有色颜料的步骤，以使可见亚层部分的颜色沿建筑板改变，或使孔隙中的亚层部分形成图案。
在施加压力后，该表面层可包含压花部分，且其中一部分亚层在压花表面部分下比在非压花表面部分下被更多地压缩。
该方法可进一步包括优选在压制前在所述木单板上施加具有耐磨粒子的保护贴面。
亚层可进一步包含有色颜料和/或着色剂。
亚层可包含耐磨粒子。
根据本发明的第三方面，提供一种建筑板。该建筑板包含含木单板的表面层、芯层和布置在表面层与芯层之间的亚层。该表面层具有延伸到木单板中的包含来自亚层的材料的表面部分。
该芯层优选是基于木纤维的芯层。
该亚层优选包含木纤维和粘合剂。
附图简述
参照显示本发明的一个实施方案的所附示意图更详细举例描述本发明。
图1图解根据本发明的一个实施方案的建筑板。
详述
图1显示具有含木单板的表面层1、芯层2和布置在表面层1与芯层2之间的亚层3的建筑板。芯层2可以是基于木纤维的板，如MDF、HDF、刨花板、胶合板、OSB等。芯层2可以是WPC(木塑复合材料)。芯层2在一个实施方案中可以是矿物板。该建筑板可以是地板、墙板、天花板、家具部件、踢脚板、模制品、镶边型材等。
使用低质量木单板作为表面层1。该单板包含裂纹和其它类似缺陷。该单板经包含木纤维4和粘合剂5的基于粉末的亚层3压在芯层2上，以使粉末浮起并填充裂纹。该板在压制后包含具有包含来自亚层3的材料的表面部分6的表面层1。包含来自亚层3的材料的表面部分6延伸到木单板中。包含来自亚层的材料的表面部分可以与表面层的其余部分齐平。“表面部分”是在背向芯层的表面层的暴露表面上可见的表面层部分。
在一个实施方案中，亚层3包含以液体形式施加的粘合剂。
可以用压花压板压制该板以使一部分亚层3在压花部分8下比在非压花表面部分下被更多地压缩。
该建筑板优选是可具有基于粉末的平衡层7的地板。在任何其它类型的建筑板上也可以施加基于粉末的平衡层7。基于粉末的平衡层7可包含木素纤维粒子或纤维素粒子和粘合剂，优选热固性粘合剂，更优选氨基树脂，如三聚氰胺甲醛树脂。该粘合剂也可以以粉末形式施加，亚层3是干粉层。在一个实施方案中，亚层3是预压层，其中在预压过程中该粘合剂尚未完全固化。
亚层3的粘合剂可以是热固性树脂，例如三聚氰胺甲醛树脂。亚层3也可包含有色颜料和耐磨粒子，如氧化铝粒子。亚层3的木纤维可以是木素纤维粒子或纤维素粒子。亚层3的木纤维可以至少部分漂白。亚层可包含起泡剂。木单板可以被软木单板或石单板(stone veneer)替代。
亚层3可以以200-600克/平方米，优选300-500克/平方米，如大约400克/平方米的量施加。为亚层3施加的粘合剂的量可以为100-300克/平方米，优选150-250克/平方米，如大约200克/平方米。亚层3可包含30-80重量％的量，优选40-60重量％，如大约50重量％的量的粘合剂。
在一个实施方案中，制成的建筑板在压制后可以为6-25毫米厚，优选8-15毫米厚，而芯层可以为5-22毫米厚，优选7-14毫米厚。亚层在压制后可以为0.1-2毫米厚。
不排除使用施加在该单板上的具有耐磨粒子的保护贴面，这可提高木单板的耐磨性。也可以使用通过下述制造方法制成的干和湿贴面：其中例如将干或湿形式的热固性树脂与氧化铝而不与任何纤维混合。在压制前可以例如在木单板上施加与三聚氰胺粉末混合的氧化铝粒子，并可以在压制后没有任何表面涂布的情况下获得耐磨表面。在压制前可以在该表面层上施加干和湿贴面。在压制前可以在该单板上施加例如粉末形式的蜡。在压制后也可以在该表面层上施加清漆。也可以在压制前在该单板上或压制后在该表面层上施加保护箔。
也考虑为该建筑板提供第二表面层(未显示)，其包含上述类型的木单板。在第二表面层与上述类型的芯层的第二表面之间布置上述类型的亚层。第二表面层具有延伸到木单板中的包含来自亚层的材料的表面部分。芯层的第二表面背向上文参照图1描述的表面层。在这一实施方案中，上文参照图1描述的表面层被视为第一表面层。
该建筑板可通过包含下列步骤的方法制造：
·在基于木纤维的芯层上施加木纤维粉末和粘合剂，以获得亚层；
·在所述亚层上施加木单板，其包含穿过所述单板的孔隙，
·施加热和压力以将所述单板、所述亚层和所述基于木纤维的芯层粘合在一起，其中一部分木纤维粉末和粘合剂被压入所述孔隙中。
该方法优选包括施加起泡剂的步骤。起泡剂可促进木纤维粉末和试剂移动到孔隙中。
该木纤维粉末可包含木素纤维粒子或纤维素粒子。
该方法可包括施加不同有色颜料的步骤，以使可见亚层部分的颜色沿建筑板改变，或使孔隙中的亚层部分形成图案。

Claims (23)

1.一种建筑板，其包含：
含木单板的表面层(1)，
基于木纤维的芯层(2)，和
布置在表面层(1)与基于木纤维的芯层(2)之间的亚层(3)，其中亚层(3)包含木纤维(4)和粘合剂(5)，
其中表面层(1)具有延伸到所述木单板中的包含来自亚层(3)的材料的表面部分(6)。
2.如权利要求1中所述的建筑板，其中包含来自亚层(3)的材料的表面部分(6)与表面层(1)的其余部分齐平。
3.如权利要求1或2中所述的建筑板，其中表面层(1)包含压花部分(8)且其中一部分亚层(3)在压花部分(8)下比在非压花表面部分下被更多地压缩。
4.如前述权利要求任一项中所述的建筑板，其中亚层(3)包含有色颜料和/或着色剂。
5.如前述权利要求任一项中所述的建筑板，其中亚层(3)包含耐磨粒子。
6.如前述权利要求任一项中所述的建筑板，其中所述建筑板是包含基于粉末的平衡层(7)的地板。
7.如前述权利要求任一项中所述的建筑板，其中所述木单板包含孔隙和/或裂纹，其中亚层(3)填充所述木单板的孔隙和/或裂纹。
8.如前述权利要求任一项中所述的建筑板，其进一步包含布置在表面层(1)上的包含耐磨粒子的保护贴面。
9.如前述权利要求任一项中所述的建筑板，其中亚层(3)中的粘合剂是热固性树脂。
10.如前述权利要求任一项中所述的建筑板，其中亚层(3)中的粘合剂(19)是三聚氰胺甲醛树脂。
11.如前述权利要求任一项中所述的建筑板，其中亚层(3)包含起泡剂。
12.如前述权利要求任一项中所述的建筑板，其中所述表面层是软木层。
13.一种建筑板，其包含：
含木单板的表面层(1)，
基于木纤维的芯层(2)，和
布置在表面层(1)与基于木纤维的芯层(2)之间的亚层(3)，其中亚层(3)包含木纤维(4)、粘合剂(5)和耐磨粒子，
其中表面层(1)具有延伸到所述木单板中的包含来自亚层(3)的材料的表面部分(6)。
14.一种建筑板，其包含：
含木单板的表面层(1)，
基于木纤维的芯层(2)，和
布置在表面层(1)与基于木纤维的芯层(2)之间的亚层(3)，其中亚层(3)包含木纤维(4)、粘合剂(5)和有色颜料和/或着色剂，
其中表面层(1)具有延伸到所述木单板中的包含来自亚层(3)的材料的表面部分(6)。
15.一种建筑板，其包含：
含木单板的表面层(1)，
基于木纤维的芯层(2)，和
布置在表面层(1)与基于木纤维的芯层(2)之间的亚层(3)，其中亚层(3)包含木纤维(4)和粘合剂(5)，且
其中表面层(1)具有延伸到所述木单板中的包含来自亚层(3)的材料的表面部分(6)，且
其中表面层(1)包含压花部分(8)且其中一部分亚层(3)在压花部分(8)下比在非压花表面部分下被更多地压缩。
16.一种制造建筑板的方法，所述方法包括：
·在基于木纤维的芯层(2)上施加木纤维粉末和粘合剂，以获得亚层(3)；
·在亚层(3)上施加木单板，其包含穿过所述单板的孔隙，
·施加热和压力以将所述单板、亚层(3)和基于木纤维的芯层(2)粘合在一起，其中一部分木纤维粉末和粘合剂被压入所述孔隙中。
17.如权利要求16中所述的方法，其进一步包括在亚层(3)中施加起泡剂。
18.如权利要求16或17中所述的方法，其中所述木纤维粉末包含木素纤维粒子或纤维素粒子。
19.如权利要求16-18任一项中所述的方法，其进一步包括施加不同有色颜料，以使可见亚层部分的颜色沿建筑板改变，或使孔隙中的亚层部分形成图案。
20.如权利要求16-19任一项中所述的方法，其中在施加压力后，所述木单板包含压花部分(8)，且其中一部分亚层(3)在压花表面部分(8)下比在非压花表面部分下被更多地压缩。
21.如权利要求16-20任一项中所述的方法，其进一步包括优选在压制前在所述木单板上施加具有耐磨粒子的保护贴面。
22.如权利要求16-21任一项中所述的方法，其中亚层(3)包含有色颜料和/或着色剂。
23.如权利要求16-22任一项中所述的方法，其中亚层(3)包含耐磨粒子。
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