CN110753614A - 适于形成地板覆盖物的面板、生产面板的方法、粘合剂前体的用途 - Google Patents

适于形成地板覆盖物的面板、生产面板的方法、粘合剂前体的用途 Download PDF

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CN110753614A
CN110753614A CN201880003818.5A CN201880003818A CN110753614A CN 110753614 A CN110753614 A CN 110753614A CN 201880003818 A CN201880003818 A CN 201880003818A CN 110753614 A CN110753614 A CN 110753614A
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layer
panel
precursor
impregnated paper
resin
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托马斯·卢克·马丁·贝尔特
安东尼·德莱维特
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CHINAFLOORS TIMBER (CHINA) Co.,Ltd.
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Champion United International
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Abstract

一种面板,适于通过组装彼此相邻的多个所述面板而形成地板覆盖物,所述面板具有基本平坦的设计,具有平坦的顶侧和平坦的底侧,所述面板由层状结构组成,所述层状结构包括:防水的芯层;顶层,所述顶层粘附在所述芯层的顶侧,其中所述顶层包括至少一个固化树脂浸渍纸层;位于所述芯层和所述顶层之间的粘合剂层,其特征在于,所述粘合剂层是固化的混合物,所述混合物包含:聚合物粘合剂化合物;以及另外的成分,其是:至少一种树脂组分,其也存在于固化树脂浸渍纸中,并且不包括在聚合物粘合剂化合物中;或者环氧树脂。

Description

适于形成地板覆盖物的面板、生产面板的方法、粘合剂前体的 用途
技术领域
本发明涉及一种面板,其适于通过组装彼此相邻的多个所述面板而形成地板覆盖物,所述面板具有基本平坦的设计,具有平坦的顶侧和平坦的底侧,所述面板由层状结构组成,该层状结构包括:
-防水的芯层;
-顶层,其粘附在所述芯层的顶侧,其中顶层包括至少一个固化树脂浸渍纸层;
-位于芯层和顶层之间的粘合剂层。
本发明还涉及一种生产这种面板的方法,以及粘合剂前体在这种方法中的用途。
背景技术
从US7763345中已知上述面板,其公开了在芯层与脲-甲醛浸渍纸层之间使用聚氨酯粘合剂。根据本发明,由该申请得到的粘合剂层与芯之间的粘合强度是令人满意的;然而,粘合剂层与脲-甲醛浸渍纸层之间的粘合强度不足以达到预期用途。
在整个该申请中,防水意味着上述材料或层在潮湿条件下不会劣化,这是本领域中已知的词语含义。在EN13229中公开了一种常用的测试方法:使芯板膨胀。根据层压板的行业标准,膨胀率<16%被认为是低的。如本发明所述的“防水”层的膨胀率在浸没24小时后将<1%,更优选<0.1%。
在用于地板覆盖物的面板的技术领域中,当顶层包括至少一个固化树脂浸渍纸层时,通常是具备吸引力的。与常规塑料层相比,这些树脂浸渍纸层对人体健康的危害较小,因为它们的增塑剂含量非常低,或者甚至为零。此外,这些层具有合适的性质,可用作装饰层和耐磨层两者—这些是顶层的主要功能。选择芯材料以使其具有足够的刚性和较轻的重量,以用于其预期用途。
这种面板的主层和顶层通常在单独的工艺中生产,其中顶层通过在压力下加热(高压层压)而被固化。通常,顶层包含许多层,例如5至8个层,从而生产出具有足够的尺寸稳定性和刚度的整体顶层以用于进一步处理。这些层通常依赖于使用所谓的牛皮纸来获得结构稳定性。
通过首先在芯层上施加反应性粘合剂层,并在压力下在粘合剂层上施加顶层而将顶层粘附至芯层。
上述生产方法需要两个固化步骤:一个用于顶层(高压层压),一个用于固化粘合剂层。这导致在所需能量和时间方面的更高成本。此外,所生产的单独顶层应具有足够的自身完整性以进行进一步处理。
为了达到这个目标,层状顶层需要足够厚(至少0.4毫米,通常约0.8毫米至1.0毫米)。这种由纤维素材料制成的层状顶层是天然吸湿的。这意味着当顶层粘附到芯上时,最终的层压产品也将是吸湿的。当室内湿度升高时,顶层将膨胀,结果最终的层压产品将开始向下弯曲。相反,当室内湿度降低时,顶层将收缩,结果最终的层压产品将开始向上弯曲。为了防止这种弯曲,芯需要足够刚性以抵消收缩和膨胀力。粘附在芯的底侧上的背衬层几乎是为了平衡张力而强制需要的。因此,在防水芯的上方使用浸渍纸顶层是昂贵的,因为芯需要厚且刚性以防止弯曲。
即使采取上述附加措施,当应用该方法时,最终获得的层状结构的尺寸稳定性在一定程度上仍可能受到损害。
发明内容
本发明的目的是限制或消除生产面板的已知方法的上述缺点。理想地,该新的方法调整为使得面板更容易生产,更具成本效益,并且具有改进的尺寸稳定性。
具体实施方式
根据本发明的第一方面,通过提供上述类型的面板而满足了上述目的,其特征在于:
粘合剂层是固化的混合物,该混合物包含:
-聚合物粘合剂化合物;以及
-另外的成分,其是:
○至少一种树脂组分,其也存在于固化树脂浸渍纸中,并且不包括在聚合物粘合剂化合物中,或者
○环氧树脂。
因此,粘合剂层具有混合特性,因为它具有聚合物粘合剂化合物,该聚合物粘合剂化合物使粘合剂层通常兼容于粘合至防水芯层,并且该粘合剂层具有另外的成分,该另外的成分赋予了粘合剂层粘合至树脂浸渍纸层的兼容能力。
所述另外的成分是树脂组分,其也存在于固化树脂浸渍纸中,并且不包括在聚合物粘合剂化合物中。发现也是有效的替代方案是环氧树脂。
根据本发明的粘合剂层不仅允许防水芯层和顶层之间的令人满意的粘合,而且还允许与已知的生产方法相比显著简化的生产方法。
包含能够与纸层中的热固性脲-甲醛聚合物反应(键合)的另外的成分提供了本发明旨在带来的益处。
优选地,在根据本发明的面板中,防水芯层由矿物材料或热塑性材料制成。
对于防水芯层的材料,可以考虑多种材料,只要它们适合于预期用途即可,这要求它们含有少于30wt.%的纤维素和/或植物材料。
作为矿物材料,可以使用氧化镁和/或氢氧化镁与合适的粘结剂的组合。合适的粘结剂是氯化镁、硫酸镁、硫酸铁、钾盐、塑料材料或粘合剂,或这些化合物的组合。作为替代的矿物材料,可以考虑波特兰水泥基材料。
作为热塑性材料,PVC或其他乙烯基化合物通常是合适的,还有PE、PU或PP。
特别地,在根据本发明的面板中,优选聚合物粘合剂化合物是聚氨酯或聚酯。
聚合物粘合剂优选是热活化型粘合剂,其包含主树脂(优选为聚氨酯或聚酯)和硬化剂(例如MDI异构体:4,4'-二苯基甲烷二异氰酸酯)。
主树脂需要通过热量来活化以与硬化剂反应。主树脂与硬化剂的反应导致粘合剂的固化。
进一步优选地,在根据本发明的面板中,所述至少一种树脂组分是脲、苯酚和/或聚氨酯。
可用于本发明的环氧树脂的优选实例是聚-1,4-丁烯己二酸酯和/或双酚A环氧树脂。
进一步优选地,在根据本发明的面板中,固化树脂浸渍纸层包含脲-甲醛或聚氨酯作为树脂。
在根据本发明的面板中,特别优选的是,顶层包含最多一个或两个固化树脂浸渍纸层。
这样的顶层以最少的层实现,对于装饰层和/或耐磨层具有令人满意的功能,同时它显著降低了纸层的吸湿力。
对于其组装地板覆盖物的适用性,优选的是,根据本发明的面板具有至少四个基本上线性的侧边缘。
此外,特别优选的是,线性的侧边缘包括至少一对相反的侧边缘,这些侧边缘设置有互连耦合装置,用于将一个面板互连在另一个面板内。例如,这些耦合装置可以根据本领域普遍存在的众所周知的凹槽/舌片类型来设计。
借助于这种耦合装置,可以组装所谓的自由浮动的地板覆盖物,而不需要用水泥胶以固定方式将相邻的面板彼此附接。
在根据本发明的面板的特定实施例中,它还包括粘附到所述芯层的底侧的底层,其中底层包括至少一个固化树脂浸渍纸层。
在第二方面,本发明提供了一种生产根据第一方面的面板的方法,包括以下步骤:
a)提供防水的芯层;
b)在芯层的顶侧上施加粘合剂前体层;
c)使粘合剂前体层干燥;
d)在干燥的粘合剂前体层上施加至少一个未固化树脂浸渍纸层;
e)对在步骤d)中获得的组件施加压力和热量,使得干燥的粘合剂前体层和未固化树脂浸渍纸中的树脂同时活化。
整个方法要求一个需要压力和热量的步骤,并且在该步骤中,粘合剂层和树脂都被活化以允许形成最终产品,该最终产品在所形成的组件冷却之后获得。因此,该方法比已知的方法耗费的时间和能量要少。
此外,由于该方法允许将未固化树脂浸渍纸层直接施加到粘合剂层上,因此没有像已知方法那样对顶层的单独完整性有要求。因此,可以使用较少的层,并且实际上可以使用1或2个层作为顶层,这进一步降低了所需的成本和时间,并且有利于如上所述的最终产品的吸湿性。
在该背景下,优选在步骤d)中,在部分固化的粘合剂层的上方施加最多一个或两个未固化树脂浸渍纸层。上面已经讨论了这些优点。
此外,应注意,最终获得的产品具有改进的尺寸稳定性,因为纸层的数量是有限的。
在根据本发明的方法中,特别优选的是,粘合剂前体是混合物,该混合物包含:
-反应性混合物,其为聚合物粘合剂化合物的前体;以及
-另外的成分,其是:
○至少一种树脂组分,其也存在于未固化树脂浸渍纸中,并且不包含在聚合物粘合剂化合物的前体中,或者
○环氧树脂的前体。
在上面的背景下,术语“前体”用于表示能够进一步反应以形成所示类型的聚合物结构的组合物。
术语“树脂组分”是指来自形成在浸渍纸中使用的未固化树脂的混合物中的一种组分。
优选地,粘合剂前体含有硬化剂,尤其是用于聚合物粘合剂化合物(例如PU或PE)的前体的硬化剂。
在步骤c)中,干燥行为允许存在于粘合剂前体的混合物中的任何溶剂在温和加热下蒸发。干燥步骤不会促使粘合剂前体已经反应成完全固化的粘合剂层。在根据本发明的方法中,防水的芯层优选由矿物材料或热塑性材料制成。上面已经讨论了这种材料的适当的实例。
类似于本发明的第一方面,在根据本发明的方法中,以下特征是优选的:
-聚合物粘合剂化合物是聚氨酯或聚酯。
-所述至少一种树脂组分是脲、苯酚和/或聚氨酯。
-未固化树脂浸渍纸层包含脲-甲醛或聚氨酯作为树脂。
同时,并且类似于在根据本发明的上述方法中顶层在芯层的顶侧上的粘合,底层可以粘附到所述芯层的底侧,其中底层类似地包括至少一个固化树脂浸渍纸层。
本发明的第三方面涉及粘合剂前体用于将至少一个未固化树脂浸渍纸层粘附到芯层的一侧上的用途,其中粘合剂前体是混合物,该混合物包括:
-反应性混合物,其为聚合物粘合剂化合物的前体,以及
-另外的成分,其是:
至少一种树脂组分,其也存在于未固化树脂浸渍纸中,并且不包含在聚合物粘合剂化合物的前体中,或者
环氧树脂的前体。
已经鉴于本发明的第二方面描述了这种用途的优点。
在根据本发明的用途的优选方式中,将粘合剂前体施加在芯层的所述一侧上,随后在将至少一个未固化树脂浸渍纸层粘附到芯层上之前对粘合剂前体进行干燥。

Claims (18)

1.一种面板,适于通过组装彼此相邻的多个所述面板而形成地板覆盖物,所述面板具有基本平坦的设计,具有平坦的顶侧和平坦的底侧,所述面板由层状结构组成,所述层状结构包括:
-防水的芯层;
-顶层,所述顶层粘附在所述芯层的顶侧,其中所述顶层包括至少一个固化树脂浸渍纸层;
-位于所述芯层和所述顶层之间的粘合剂层,
其特征在于,
所述粘合剂层是固化的混合物,所述混合物包含:
-聚合物粘合剂化合物;以及
-另外的成分,其是:
至少一种树脂组分,其也存在于固化树脂浸渍纸中,并且不包括在聚合物粘合剂化合物中,或者
环氧树脂。
2.根据权利要求1所述的面板,其中,所述另外的成分是环氧树脂,包括聚-1,4-丁烯己二酸酯和/或双酚A环氧树脂。
3.根据权利要求1或2所述的面板,其中,所述芯层由矿物材料或热塑性材料制成。
4.根据权利要求1至3中任一项所述的面板,其中,所述聚合物粘合剂化合物是聚氨酯或聚酯。
5.根据权利要求1至4中任一项所述的面板,其中,所述至少一种树脂组分是脲、苯酚和/或聚氨酯。
6.根据权利要求1至5中任一项所述的面板,其中,所述固化树脂浸渍纸层包含脲-甲醛或聚氨酯作为树脂。
7.根据权利要求1至6中任一项所述的面板,其中,所述顶层包含最多一个或两个固化树脂浸渍纸层。
8.根据权利要求1至7中任一项所述的面板,其中,所述面板具有至少四个基本上线性的侧边缘。
9.根据权利要求8所述的面板,其中,所述线性的侧边缘包括至少一对相反的侧边缘,所述相反的侧边缘设置有互连耦合装置,用于将一个面板互连在另一个面板内。
10.一种生产根据权利要求1至9中任一项所述的面板的方法,包括以下步骤:
a)提供防水的芯层;
b)在所述芯层的顶侧上施加粘合剂前体层;
c)使所述粘合剂前体层干燥;
d)在干燥的粘合剂前体层上施加至少一个未固化树脂浸渍纸层;
e)对在步骤d)中获得的组件施加压力和热量,使得干燥的粘合剂前体层和未固化树脂浸渍纸中的树脂同时活化。
11.根据权利要求10所述的方法,其中,在步骤d)中,在所述粘合剂层的上方施加最多一个或两个未固化树脂浸渍纸层。
12.根据权利要求10或11所述的方法,其中,所述粘合剂前体是混合物,所述混合物包含:
-反应性混合物,其为聚合物粘合剂化合物的前体;以及
-另外的成分,其是:
至少一种树脂组分,其也存在于所述未固化树脂浸渍纸中,并且不包含在所述聚合物粘合剂化合物的前体中,或者
环氧树脂的前体。
13.根据权利要求10至12中任一项所述的方法,其中,所述芯层由矿物材料或热塑性材料制成。
14.根据权利要求10至13中任一项所述的方法,其中,所述聚合物粘合剂化合物是聚氨酯或聚酯。
15.根据权利要求10至14中任一项所述的方法,其中,所述至少一种树脂前体是脲、苯酚和/或聚氨酯。
16.根据权利要求10至15中任一项所述的方法,其中,所述未固化树脂浸渍纸层包含脲-甲醛或聚氨酯作为树脂。
17.粘合剂前体用于将至少一个未固化树脂浸渍纸层粘附到芯层的一侧上的用途,其中,所述粘合剂前体是混合物,所述混合物包括:
-反应性混合物,其为聚合物粘合剂化合物的前体,以及
-另外的成分,其是:
至少一种树脂组分,其也存在于未固化树脂浸渍纸中,并且不包含在所述聚合物粘合剂化合物的前体中,或者
环氧树脂的前体。
18.根据权利要求17所述的用途,其中,将所述粘合剂前体施加在所述芯层的所述一侧上,随后在将至少一个未固化树脂浸渍纸层粘附到所述芯层上之前对所述粘合剂前体进行干燥。
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