阅读说明：本技术 轻量化面砖 (Light weight face brick ) 是由 张兆毅 简君潔 张雅媖 王悦筑 于 2018-07-23 设计创作，主要内容包括：本发明轻量化面砖,包含一面砖本体,是由硬质树脂发泡体所构成,其中包含多个泡孔,以及一漆面层,其是铺设于该面砖本体表面上。硬质树脂发泡体的密度介于0.2～0.45克/立方厘米之间。根据本发明所指出的轻量化面砖可有效减少已知磁砖过重问题,并赋予面砖较佳的隔热与隔音效果。(The invention relates to a light-weight face brick, which comprises a face brick body and a paint surface layer, wherein the face brick body is composed of a hard resin foaming body and comprises a plurality of foam holes, and the paint surface layer is laid on the surface of the face brick body. The density of the hard resin foam is 0.2 to 0.45 g/cc. Lightweight tiles in accordance with the teachings of the present invention can effectively reduce the problem of known tiles being too heavy and impart better thermal and acoustical insulation to the tiles.)

1. A lightweight tile, comprising:

a tile body composed of a rigid resin foam body including a plurality of cells, and

a paint surface layer which is laid on the surface of the face brick body,

wherein the density of the face brick body is between 0.2 and 0.45 g/cubic centimeter.

2. The lightweight tile according to claim 1, wherein the tile body has a density of between 0.25 and 0.4 g/cc.

3. The lightweight tile according to claim 1, wherein the open-closed porosity of the cells in the tile body is between 0.05 and 0.2.

4. The lightweight tile according to claim 3, wherein the open-closed porosity of the cells in the tile body is between 0.1 and 0.15.

5. The lightweight tile according to claim 1, wherein the hard resin foam is obtained by foaming an isocyanate compound, a polyol, a foaming agent and a catalyst.

6. The lightweight tile according to claim 5, wherein the isocyanate-based compound is a polyisocyanate.

7. The lightweight tile according to claim 5, wherein the polyol is an aromatic polyester polyol.

8. The lightweight tile according to claim 5, wherein the polyol is an aliphatic polyester polyol.

9. The light weight tile according to claim 1, wherein the rigid resin foam further comprises a glass fiber.

10. A light weight tile as claimed in claim 1, in which the tile body is further provided with a projection thereon.

Technical Field

The present invention relates to tiles, also commonly referred to as tiles. In particular, it relates to a lightweight tile suitable for use in wall coverings.

Background

Tiles are often used in buildings, such as in the interior and exterior walls of buildings, floors, or other surfaces that require decoration, such as cooking surfaces in kitchens. The known face brick is a product formed by firing ceramic clay, feldspar, pottery stone, quartz and other materials at high temperature. If the glazed surface is treated, it is also called glazed brick, and if it is not glazed, it is called unglazed brick. Tiles are therefore often referred to as tiles, or tiles.

The types of tiles are roughly classified into three types, i.e., ceramic, stone and porcelain, depending on the materials used. In general, ceramic and stone are glazed bricks, and porcelain is a quartz brick with low water absorption and high hardness.

When used for wall decoration and building material protection, especially for indoor walls, the basic requirements are color brilliance and shape change, and the appearance of texture and overall matching are taught, and no special requirements are made on hardness and mechanical strength, so that cheap ceramic bricks are usually used.

However, when the tiles are applied to the outer wall surface, the tiles may be peeled off due to careless construction, defective quality of the tiles, or the influence of thermal expansion and contraction over the years. Since the known magnetic tiles are made of ceramic clay, feldspar, pottery stone, quartz, etc., and have a density of 2 g/cc or more, the weight of the manufactured tile body is not light. Once the tiles are peeled off the wall surface and fall, combined with the gravitational acceleration, there is a strong possibility of damage to the person or property, especially if the tiles are extensively peeled off. Therefore, people are injured or financial loss is caused by peeling off old building outer wall tiles, which is often heard in news. Furthermore, when the tile size is large, the weight is heavy, which causes troubles in the construction of the outer wall of the high-rise building and increases the risk of the tile peeling off from the wall surface.

Further, as described above, it is known that the ceramic tiles are made of materials such as soil, stone, etc. which are similar to those used for the concrete wall, so that the ceramic tiles and the concrete have almost the same heat transfer coefficient and sound insulation effect. However, the known concrete wall surface has imperfect heat insulation and sound insulation effects, and if a higher heat insulation and sound insulation effect is to be obtained, the wall surface needs to be thickened, which causes problems of high construction cost, construction troubles, heavy buildings, and the like. In order to solve the problem caused by the thickened wall surface, the known technicians can coat a heat insulation layer on the wall surface or erect a heat insulation plate to improve the heat insulation effect of the concrete wall surface, or erect a sound insulation plate on the wall surface to strengthen the sound insulation effect of the concrete. However, this causes problems such as the aesthetic appearance of the wall surface being damaged and the construction being repeated, and also increases the cost of the construction.

Therefore, if a light-weight tile can be developed, it is desirable to have additional functions such as heat insulation and sound insulation, and it is expected by those in the field of building materials.

Disclosure of Invention

Accordingly, an object of the present invention is to provide a light-weight tile which can reduce the trouble of construction and the damage of the tile when the tile is carelessly peeled off.

In order to achieve the above object, the present invention provides a light weight face brick, which comprises a face brick body and a paint surface layer laid on the surface of the face brick body. The tile body is composed of a hard resin foam body and comprises a plurality of foam holes.

In one or more embodiments, the density of the tile body is preferably between 0.2 and 0.45 g/cc.

In one or more embodiments, the cells are composed of a plurality of open cells and a plurality of closed cells, and a ratio (open/closed porosity) of the number of the open cells to the number of the closed cells is between 0.05 and 0.2.

In one or more embodiments, the lightweight face brick of the present invention has at least one protrusion on the lower side, thereby increasing the adhesion between the face brick of the present invention and the cement and reducing the risk of peeling off and falling off the wall surface.

The lightweight face brick of the invention has a density lower than that of known tiles, so that the requirement of lightweight can be effectively met. The light weight face brick can be easily manufactured in a large area and then cut according to the required size, so that the manufacturing cost can be effectively reduced. Or can be formed into various shapes or cut into various shapes and sizes as required. The face brick can easily change the required appearance through the color and the type of the paint surface layer laid on the face brick body.

In addition, the facing brick body is made of the hard resin foaming body, and better heat insulation and sound insulation effects can be further provided.

Drawings

FIG. 1 is a schematic, partially cross-sectional view of one embodiment of the lightweight tile of the present invention;

FIG. 2 is a schematic, partial cross-sectional view of another embodiment of the lightweight tile of the present invention.

Detailed Description

In order to make the present invention more comprehensible to those skilled in the art through the description of the present invention, the following description is further provided in conjunction with the accompanying drawings. It will be appreciated by those skilled in the art that the following descriptions are provided only for illustrating the present invention and illustrating the scope of the preferred embodiments and are not intended to limit the scope of the present invention.

Fig. 1 is a schematic partial cross-sectional view of a lightweight tile according to an embodiment of the invention. The invention relates to a lightweight face brick 1, which mainly comprises a face brick body 10 and a paint surface layer 12. The finish 12 is applied to a surface of the tile body 10, and the surface includes at least an upper surface 18.

The tile body 10 is made of a rigid resin foam, and contains a plurality of cells containing air, so that it has a low density, and therefore, the weight of the lightweight tile 1 of the present invention can be effectively reduced. In one or more embodiments, the tile body 10 preferably has a density of between 0.2 and 0.45 g/cc, and more preferably between 0.25 and 0.4 g/cc. Lower densities may result in lighter weight tiles, but may result in reduced overall mechanical strength. Conversely, the higher density will increase the weight of the tile, losing the meaning of light weight, and also affecting its heat and sound insulation effects.

In one or more embodiments, the cells are comprised of closed cells 14 and open cells 16. The ratio of the number of open cells 16 to the number of closed cells 14 in the tile body 10 is defined herein as the open-to-closed cell ratio.

In one or more embodiments, the open/close porosity of the cells in the tile body 10 is preferably between 0.05 and 0.2, and more preferably between 0.1 and 0.15. When the opening-closing porosity is too high, the heat insulating effect is lowered. On the other hand, when the open/close porosity is too low, the desired sound absorbing effect cannot be obtained. On the other hand, the existence of the open cells 16 can form an uneven surface on the surface of the tile body 10, thereby increasing the adhesion effect with the paint finish 12 and the adhesion effect with cement later in the mud construction, so that the lightweight tile 1 of the present invention is less prone to peel off from the wall surface.

In one or more embodiments, the tile body 10 is made of a rigid resin foam. The rigid resin foam is obtained by foaming an isocyanate compound and a Polyol (Polyol) with a foaming agent and a catalyst added. The kind and amount of the isocyanate compound, the polyol, the blowing agent and the catalyst are not particularly limited in the present invention, and any compounds having the above-defined characteristics can be used in the present invention. The skilled person can select the proper material types and adjust the proper composition ratio to obtain the hard resin foam with the desired properties.

In one or more embodiments, the isocyanate-based compound useful in the present invention comprises a diisocyanate (Di-isocyanate). The aforementioned diisocyanates include Toluene Diisocyanate (TDI), Isophorone diisocyanate (IPDI), diphenylmethane diisocyanate (4,4' -diphenylmethyl diisocyanate, MDI), dicyclohexylmethane diisocyanate (HMDI), Lysine Diisocyanate (LDI), and Polyisocyanate (polyisocynate, MDI), but are not limited thereto. In one or more embodiments, polyisocyanates (Polyisocyanate, PolyMDI) are preferred.

In one or more embodiments, the polyols useful in the present invention include, but are not limited to, Aromatic polyester polyols (Aromatic polyester polyols), Aliphatic polyester polyols (Aliphatic polyester polyols), and Polyether polyols (Polyether polyols). In one or more embodiments, aromatic polyester polyols are preferred.

In one or more embodiments, in order to further enhance the mechanical strength of the tile body 10, glass fibers may be added to the raw materials for foaming and embedded in the rigid foam when the rigid resin foam is prepared. Or other additives capable of reinforcing the hard resin foam, such as nano-particles, may be added to the raw materials to prepare the hard foam of the nano-reinforced composite material, but the invention is not limited thereto.

The surface finish layer 12 laid on the tile body 10 is not particularly limited in the present invention as long as it can be applied to the present invention as a paint for coating on the hard resin foam. The skilled artisan can select the desired color, appearance and characteristics of the painted surface after application. For example, but not exclusively, for making the lightweight tiles 1 according to the invention look more like known tiles, Stone paint (Stone flash paint), also known as imitation Stone paint, can be applied on top of it. In addition, to further enhance the flame resistance of the tile of the present invention, a known fire retardant paint may be used as the finish 12 of the tile of the present invention, and applied to the surface of the tile body 10.

In one or more embodiments, the finish 12 can be applied to the lower surface 20 or side surfaces, as desired, in addition to the upper surface 18 of the tile body 10.

The method of applying the paint finish 12 to the tile body 10 is not particularly limited, and any known method of applying paint to the tile body 10 to form a paint finish can be used in the present invention. Examples of the method include, but are not limited to, coating, spraying, dipping, and vapor deposition.

FIG. 2 is a schematic, partial cross-sectional view of another embodiment of the lightweight tile of the present invention. To enhance the adhesion of the lightweight tile 1 of the present invention to cement and to reduce the possibility of peeling off in the future. The tile body 10 may further include a projection 22. In one or more embodiments, the protrusion 22 may be disposed on the side surface in addition to the lower surface 20. The size, shape and position of the protrusion 22 are not particularly limited in the present invention, and any protrusion can be used as long as it can increase the contact area with cement or form a physical engagement structure. The cross-sectional shape of the protruding portion 22 is, for example, a circle, an ellipse, a triangle, a square, a polygon, a star, an i-shape …, but is not limited thereto.

In one or more embodiments, the aforementioned projecting portion 22 is formed integrally with the tile body 10. For example, the hard resin foam is foamed to produce the lightweight tile of the present invention by using a mold design, and then molded. In one or more embodiments, the aforementioned protruding portion 22 can also be prepared separately and then fixedly coupled to the tile body 10 by any known coupling method. For example, an adhesive may be used to join the two.

Since tiles are known to have densities of about 2.5 g/cc, the density of the lightweight tiles of the present invention is only between 0.2 and 0.45 g/cc. Thus, at the same volume, the weight of the lightweight tile of the present invention is less than 1/5, which is the weight of known tiles, and the weight is significantly reduced by more than 80%. In addition, since the body of the lightweight tile of the present invention is a hard resin foam, many foamed cells are filled therein. Therefore, the resin plate has better mechanical strength, heat insulation and sound insulation compared with a resin plate with the same weight.