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CN101868332A - 层压地板的再生 - Google Patents

层压地板的再生 Download PDF

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Publication number
CN101868332A
CN101868332A CN200880116831A CN200880116831A CN101868332A CN 101868332 A CN101868332 A CN 101868332A CN 200880116831 A CN200880116831 A CN 200880116831A CN 200880116831 A CN200880116831 A CN 200880116831A CN 101868332 A CN101868332 A CN 101868332A
Authority
CN
China
Prior art keywords
particles
floor
core
layer
surface 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
CN200880116831A
Other languages
English (en)
Inventor
D·佩尔万
K·林德格伦
J·雅各布松
N·哈坎松
E·布克
G·齐格勒
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 Belgium BVBA
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 Belgium BVBA filed Critical Valinge Innovation Belgium BVBA
Publication of CN101868332A publication Critical patent/CN101868332A/zh
Pending legal-status Critical Current

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Abstract

基于将面板(1)分离成颗粒将层压地板再生，其中，颗粒借助粘合剂连接而形成新的片状材料。建筑面板包括表面层和木纤维基芯，木纤维基芯包括氧化铝颗粒。

Description

层压地板的再生
技术领域
本发明总体上涉及再生基于木纤维的面板，特别是层压地板(地板材料，floorings)的领域。本发明提供了一种新型片材及这种材料的生产方法。
背景技术
具体但非限制性地，本发明涉及含木纤维的片状面板、特别是层压地板的再生(再循环)。然而，本发明通常还适用于建筑面板。本发明特别适合用于由地板形成的浮动地板(浮筑式地板，floating floor)，其中所述地板由一个或多个优选防潮的装饰性层压材料或装饰性塑料材料的上层、木纤维基材料(wood-fiber-based material)或塑料材料的中间芯和优选的在芯的后侧上的下平衡层构成。
因此，下面对已知技术、已知系统的问题和本发明的目标及特征的描述，将以非限制性实例的方式最主要地针对这种应用领域并更具体地针对层压地板。应当强调：本发明可用于任意的其中地板优选具有芯和至少一个表面层的地板。本发明因此还可以用于例如具有一个或多个表面层的地板，其中所述表面层由木材、塑料材料、柔性纤维诸如针织毡、或不同材料例如木材、塑料、软木、橡胶或其它用作地板中的表面层的材料的组合形成。
层压地板通常包括6-12mm纤维板的芯、层压材料的0.2-0.8mm厚的装饰性上表面层和层压材料、塑料、纸或类似材料的0.1-0.6mm厚的下平衡层。表面层向地板提供外观和耐久性。芯提供稳定性，平衡层在相对湿度(RH)随时间发生变化时保持板材平坦。本发明总体涉及木纤维基面板、特别是层压地板的再生领域。本发明提供一种新型片材及生产这种材料的方法。
地板通常浮动地、即非胶粘地被铺设在不必是完全光滑或平坦的已有底层地板上。传统的这种浮动地板中的硬地板通常借助胶粘的突舌-凹槽接合(企口连接，tongue-and groove)连接。
除借助胶粘的突舌-凹槽接合连接的这种传统地板之外，近来已研制出无需使用胶水且转而借助所谓机械接合系统机械连接的地板。这些系统包括水平和/或垂直地锁定板材的锁定装置。
具有机械接合系统的浮动地板的主要优点是它们可以通过向内偏角调节(inward angling)、咬合(snapping-in)和沿接合边缘移动的各种组合被轻易且快速地铺设。这些地板还可以再次轻易地收起，并且再次被用在不同的地方。
最常见的芯材是具有高密度和良好稳定性的纤维板，其通常称作HDF-高密度纤维板。有时也将MDF-中密度纤维板用作芯。通常，这些芯材都具有高的质量。
HDF的生产如下：圆材诸如例如松树、落叶松或云杉被粉碎成木屑，然后在精炼机中被打破成纤维。这些纤维随后与热固性粘合剂混合，然后在挤压机中经历高压和高温。纤维借助固化的粘合剂相互粘合。
一些术语的定义
在下文中，安装的地板面板的可视表面被称作“前侧”，而该地板面板的朝向底层地板的相对侧被称作“后侧”。包含地板面板的主要部分的片状材料被称作“芯”。然后在最靠近前侧的位置上给芯覆以表面层，优选地还在最靠近后侧的位置上给芯覆以平衡层，它构成半成品，其在该半成品在后续操作中被分成多个地板元件的情况下被称作“地板板材”或“地板元件”。然后，这些地板元件沿其边缘被机械加工以获得具有接合系统的最终形状，它们被称作“地板面板”。“表面层”意指所有在最靠近地板板材前侧的位置上施加于芯上且优选覆盖整个前侧的层。“装饰性表面层”意指主要用于使地板具有装饰性外观的层。“耐磨层”涉及主要适于改善前侧的耐久性的层。
“水平平面”意指平行于表面层外部延伸的平面。“水平地”意指与水平平面平行，“垂直地”意指与水平平面垂直。“上”意指朝向前面，“下”意指朝向后面。
已知技术及其问题
上述技术可以被用于制造作为木制地板的高度自然的复制品的层压地板。近些年，石材、地砖和类似物的模仿变得越来越普遍。所有这些高级的设计都要比过去20年中产生的设计更具有吸引力，并且它们以非常低的价格被出售。
层压地板非常耐磨，并且其寿命在正常家庭环境下可超过约15-20年。在诸如商店、旅馆和类似地点这样的公共区域，其寿命可以约为5年。层压地板不能如木制地板那样通过表面磨光来修理。很多旧的层压地板因表面层受损而需要很快就更换。新的吸引人的图案和易于移除和更换地板的方式还将逐渐形成大量的仅因消费者想要更吸引人的地板而将被处理掉的层压地板。
最常见的处理掉或毁坏层压地板的方式是燃烧该产品。这引起环境污染和相当大的原材料浪费。即使在地板面板是以产生能量且气体尽可能地得到清洁的过程中燃烧的情况下，也会对环境造成相当大的负面影响。如果层压地板可以被再生和如果纤维基材料可以以成本有效的方式被用于生产其他类型的材料，优选片状材料，的话将是很有利的。
已知在HDF材料的生产过程中纤维可以被再生。还已知旧的地板面板可以被用作包装材料。所有这些应用都不能解决在即将到来的这些年中每年将要处理掉1亿立方米的层压地板这一重大问题。
发明内容
本发明旨在解决主要是层压地板必须被处理掉的问题。
本发明基于第一种基本认识，即：这种地板材料不应以产生气体且对环境具有负面影响的过程被毁掉。
本发明还基于第二种认识，即：应优选完全地重复利用旧地板的原材料，并且新的多用途的片状产品应当用旧地板的原材料来生产。新的多用途的片状产品可被用作建筑面板，优选用作新地板面板中的芯、和/或表面层和/或平衡层。
本发明的主要目标是解决打算被处理掉的旧层压面板的环境问题。
根据本发明的第一方面，提供了一种由来自旧层压地板面板的再生材料形成的建筑面板，其具有表面层和含有氧化铝颗粒的木纤维基芯(6)(基于木纤维的芯)。建筑面板优选设有平衡层。
这种新面板，其由再生的具有不同品质和材料组成的原始层压地板面板生产且包括所有的原始材料和化学品，可具有与原始面板相似或甚至更好的粘合强度、抗潮湿和冲击性。令人惊讶的效果是：如果诸如氧化铝和三聚氰胺颗粒以及涂覆或浸渍有固化的粘合剂的木纤维这样的原始材料被机械切割成小颗粒且与合适的粘合剂混合并且被压成面板(panel)，则这种材料将不对新面板的性质产生负面效果。
这种机械切割将产生具有粗糙且增大的表面部分的颗粒。这将增加粘合强度。
根据本发明的第二方面，提供了一种将旧层压地板面板再生成可用于生产建筑面板的芯的方法。该方法包括以下步骤：
a)将面板机械切割成颗粒；
b)将所述颗粒与粘合剂混合；
c)挤压混合的颗粒和粘合剂，由此形成片状材料。
附图说明
图1a-e示出了将层压地板面板切割成颗粒(刨花，particle)；
图2a-b示出了根据本发明实施例的生产包含再生材料的芯材的生产方法；
图3a-d示出了根据本发明实施例的生产方法。
具体实施方式
图1a示出了根据已知技术的层压地板面板1，其包括表面层5、芯6和平衡层7。图1c示出了表面层5。它具有耐磨度高的透明材料的上耐磨层13。这种耐磨层通常包括浸渍三聚氰胺树脂且添加有氧化铝颗粒12的透明纸。由印有图案的纸11形成的装饰层10被浸以三聚氰胺树脂，并且置于透明耐磨层13下方。耐磨层13和装饰层10被层压到芯上，并且在压力和热的作用下形成约0.2mm厚的表面层5，该芯通常是纤维基芯，诸如HDF。图1b示出了平衡层7，其通常也是浸渍三聚氰胺的纸。在湿度随时间变化时，平衡层保持地板面板平坦。透明耐磨层通常为0.05-0.10mm厚。
旧层压地板的组成可能不同。一些层压地板具有施加于地板背侧上的减音材料。这种材料可能是会在用旧层压地板制成的新板材上引起泡眼(blister)或分层的不同种类的塑料材料或其它材料。
因此，优选通过分离操作去除这种减音材料。这种分离优选用旋转刀齿滚筒(切碎滚筒，knife cylinder)完成。去除的材料可以例如被燃烧或用作各种应用中的填充物。一些塑料材料可以被再生成例如新的隔音材料。
其它层压地板不具有任何减音材料。这些类型的地板可直接用于该处理的下一步骤。
在这种操作中，还可以去除三聚氰胺表面层和平衡层。然而，根据本发明，优选循环利用包括表面层5和平衡层7在内的整个层压地板面板。
旧层压地板面板具有从小片到厚木板尺寸的不同尺寸。
这种材料必须在尺寸上优选粉碎(缩减)至0.01-10mm大小的碎屑或颗粒。这种尺寸选择可以不同方式完成。合适的器械例如是小刀或其中切割颗粒的尺寸可以通过改变可让被分离的颗粒离开切割器械的孔洞来调节的锤式粉碎机。
切割材料颗粒包括如图1d所示的三种材料组分。一些颗粒主要是木纤维14或木纤维碎屑，一些主要包括来自表面层5的部分(10，12)，诸如主要为装饰性的纸10、来自贴面层13的三聚氰胺薄片和氧化铝颗粒12，以及最后地来自平衡层的含三聚氰胺的部分15。所有颗粒优选被收集在容器中以储存用于下一切割步骤。这种首次分离可以在特定的收集站中完成。
旧层压地板的切割当然也可以通过使用标准生产设施在普通MDF和HDF设施中完成。
如果希望将含三聚氰胺的颗粒用在新的高质量的板材中，则优选地，作为切成小颗粒的替换，在分离之前砂磨表面层和平衡层。由未经砂磨的原始层压地板制成的新板材的抗弯强度和抗拉强度会低于由经砂磨的原始层压地板制成的新板材。其原因在于将木纤维粘合在光滑的三聚氰胺表面部分上非常困难。砂磨或切成小颗粒将增加三聚氰胺颗粒和纤维之间的粘合。
砂磨操作可以利用木制和层压工业中使用的标准砂磨机(sandingmachine)完成。所用砂纸的粒度约为80。
这些颗粒的尺寸还可以通过过筛减至例如0.01-1mm，并且它们现在可被用作板材制造中的原材料。
这些颗粒还可以被分离成例如三种不同的材料类型，主要是木纤维14或木纤维碎屑，主要是来自表面层5的部分(10，12)，诸如主要为装饰性的纸10和来自贴面层13(overlay，贴面纸)的三聚氰胺薄片和氧化铝12，以及最后地来自平衡层的含三聚氰胺的部分15。这些材料可以分别用于形成新的板材或者充当填充物，或者它们可以全部被包括在新板材的各个部分中。
为形成用于建筑面板或层压地板的板材，用粘合剂将不同类型的纤维和碎屑混到一起以将纤维粘合到一起，以及使板材具有某些特性，诸如抗弯强度、抗拉强度和抗湿性等。
切成颗粒或碎屑产生不同的纤维段，它们可以是原始面板中的相当长的纤维、较小的纤维和非常小的纤维或纤维粉末。浸渍三聚氰胺且在初始的HDF处理中固化的这些纤维具有非常高的质量，并且非常适于形成例如地板中的表面层。含三聚氰胺和氧化铝的碎屑具有不同性质。它们可以被用于形成地板中的高密度和耐磨的部分。
纤维段(fiber fractions)和碎屑优选分别地与粉状树脂，例如三聚氰胺树脂-Kauramin 772，混合。这使得能够形成具有不同的层且层中具有不同性质的板材。
粉状树脂/三聚氰胺的数量可以在5至25重量％之间变化。为生产标准的用于层压地板的板材，优选10-15重量％。纤维和(三聚氰胺)粉状树脂的混合可以用油漆搅拌器在罐中完成。混合时间可约为5分钟。
当不同的纤维与粉状三聚氰胺树脂混合时，不同的片段被存放在分别储存的容器中。
当然可以使用其他类型的树脂，例如三聚氰胺/尿素树脂和酚醛树脂(phenol resin)都可以以粉状或在液态条件下使用。
使用粉状树脂使得易于将不同类型的纤维和碎屑与天然木屑或玻璃纤维混合。这是种干处理。无需使用能量来进行干燥。
当使用溶液形式的树脂时，树脂必须通过例如喷洒来施加。然后，被涂覆的纤维必须被干燥，并且必须添加能量。
在这一处理阶段，还可以添加其他类型的纤维，例如原生纤维或用于制造MDF或HDF的纤维。这些纤维可以与例如粉状三聚氰胺树脂混合，并且被存放在独立容器中。
图2a示出了用于生产根据本发明的木纤维板的优选生产方法。将第一层6施加在传送带20上，所述第一层6包含与粘合剂混合的所有来自再生层压地板的颗粒。该生产方法可优选和可选地包括中间的挤压步骤，在该步骤中，利用辊筒21或连续挤压器械或类似设备来部分压缩木纤维。在此生产步骤中，纤维优选未发生固化，至少未全部固化。
此后，经预压的层在优选的连续挤压机23中在热和压力的作用下受到挤压，纤维和碎屑借助在热和压力作用下固化的粘合剂粘到一起而形成板材。层压地板的所有部分均被重复使用。也可以使用具有一个或数个开口的不连续的挤压机。
粘合剂优选是三聚氰胺甲醛树脂(melamine-formaldehyde resin)。压力优选约为300N-800N/cm2，温度可以是120-220摄氏度。挤压时间可以例如为20秒-5分钟，其取决于生产速度、面板厚度、粘合剂等。板材的密度优选为700-1000kg/m3。可以生产密度为1000-1500kg/m3的非常抗潮湿和冲击的板材。
图2b示出了用于生产根据本发明另一原理的木纤维地板面板的生产方法。在此例中，可以只使用再生的颗粒或碎屑，或者使用与原生纤维(virgin fiber)混合的再生颗粒。包含平衡层的第一层7被施加在传送机20上。包含芯层的第二层6被施加在平衡层上。这两个层优选只包含木纤维和粘合剂。第三层，表面层5，被施加在芯层6上。表面层5包含木纤维、粘合剂和耐磨颗粒。表面层5还可以包括可以使表面层具有基色的颜色染料。该生产方法可优选包括中间的挤压步骤，在该步骤中，利用辊筒21或连续挤压器械或类似设备来部分压缩木纤维。在该生产步骤中，纤维优选未发生固化，至少未全部固化。
赋予表面层5装饰特征的利用例如喷墨打印机22或其它类型的生产器械进行的打印，可以可选地与地板板材的生产一致地被使用。优选在经预压的表面上进行打印。经预压的层在印刷之后在热和压力作用下受到挤压，纤维和耐磨颗粒借助在热和压力作用下固化的粘合剂粘到一起，并且获得坚硬的表面层。
即使在此处，粘合剂也优选三聚氰胺-甲醛树脂。压力也优选约为300N-800N/cm2，温度可以是120-220摄氏度。挤压时间可以例如在20秒-5分钟之间，其取决于生产速度、面板厚度、粘合剂等。地板的密度优选为700-1000kg/m3。可以生产密度为1000-1500kg/m3的非常抗潮湿和冲击的地板。
该地板板材可以被用于形成地板面板，而无需任何附加层。或者，层压的层、颜料、印刷物等可以被用作附加表面层。
优选以连续的过程生产整个地板(floorboard，地板材)。然而也可以通过如图3a-3d所示的数个步骤来制作地板。单独的表面层5或芯层6和甚至平衡层7都可以根据本发明和如图3a所示那样生产，并且这些层可以通过胶水连接。然而，最优选的方法是利用再生材料生产芯6，并且将表面层施加在芯6上。还可以施加平衡层7。表面层5和含再生材料的平衡层7也可以直接被施加到例如HDF的芯上，并且这三个层可以连续地或在不连续的挤压机中被压成地板3。
在上述的所有替换方式中，地板3通常被切成单个地板元件2，并且它们的边缘通常被机械加工和成形成具有机械锁定系统4、4’的地板面板。所有已知的允许通过偏角调节(倾斜，angling)、水平搭扣和垂直搭扣、侧推等方式锁定的锁定系统均可使用。
单个地板元件2或地板面板1也可以被生产，并且锁定系统的部件可以例如在挤压操作中形成。地砖和石材形状的产品也可以被生产成无任何锁定系统，它们可以以传统方式通过胶粘安装在底层地板(sub-floor)上。

Claims (8)

1.一种具有表面层和木纤维基芯(6)的建筑面板，其特征在于：
所述芯包含氧化铝颗粒(12)。
2.如权利要求1所述的建筑面板，其中：
所述芯(6)还包括浸渍三聚氰胺树脂的纸的颗粒(7，10，13)。
3.如权利要求1或2所述的建筑面板，其中：
所述建筑面板为具有表面层(5)的地板面板(1)。
4.如权利要求3所述的建筑面板，其中：
所述地板面板包括平衡层(7)。
5.一种用于再生包含木纤维基芯、含热固性树脂和氧化铝的装饰性表面层的层压地板面板的方法，其特征在于该方法包括以下步骤：
d)将面板机械切割成颗粒；
e)将所述颗粒与粘合剂混合；
f)挤压混合的颗粒和粘合剂，由此形成片状材料。
6.如权利要求5所述的方法，其中：
挤压在受热条件下进行。
7.如权利要求5或6所述的方法，其中，该方法包括：
将所述颗粒与三聚氰胺甲醛树脂混合。
8.如权利要求5-7中任一项所述的方法，其中，该方法包括以下步骤：
将颗粒基本分成第一组颗粒和第二组颗粒，其中第一组颗粒大体包括木纤维，第二组颗粒大体包括三聚氰胺，然后将至少第一组颗粒与粘合剂混合。
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CN105324251B (zh) * 2013-07-02 2021-11-12 瓦林格创新股份有限公司 制造建筑镶板的方法和建筑镶板
CN104746837A (zh) * 2013-12-31 2015-07-01 阿姆斯特郎世界工业公司 混合地板产品
CN104746837B (zh) * 2013-12-31 2018-08-10 阿姆斯特郎世界工业公司 混合地板产品
CN110891780A (zh) * 2017-07-19 2020-03-17 宜家供应有限公司 实木颗粒板
CN110891780B (zh) * 2017-07-19 2022-08-23 宜家供应有限公司 实木颗粒板

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US20130095315A1 (en) 2013-04-18
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EP2212071B1 (en) 2013-06-05
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US20090145066A1 (en) 2009-06-11
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