阅读说明：本技术 多官能无机面板及其制造方法 (Multifunctional inorganic panel and method for manufacturing same ) 是由 R·阿帕雷西多斯桑托斯 于 2018-11-06 设计创作，主要内容包括：一种无机面板,其特征在于以干重百分比计,它们由1-35％铝酸钙,5-40％高岭土,作为第一填料,10-25％无定形硅酸盐,5-40％第二无机填料,碳酸钙或工业滑石,1-3％偏硅酸盐,0.2-2％氢氧化铝,0.1-0.5％聚羧酸盐,0.3-5％聚甲基丙烯酸甲酯或低TG的聚甲基丙烯酸甲酯,和1-30％纤维组成。它们可具有膜涂布的侧面。该制造方法包括下述步骤：i)形成纤维网；ii)用偏硅酸盐浸渍纤维网；iii)干燥浸渍的纤维网；iv)用包含所述组分的至少一种悬浮配混料浸渍纤维网,形成片材；(v)切割片材并嵌入,或者反之亦然；(vi)压制；(vii)活化面板芯坯件中的配混料。(Inorganic panel, characterized in that they consist, in dry weight percentages, of 1-35% calcium aluminate, 5-40% kaolin, as a first filler, 10-25% amorphous silicate, 5-40% second inorganic filler, calcium carbonate or technical talc, 1-3% metasilicate, 0.2-2% aluminum hydroxide, 0.1-0.5% polycarboxylate, 0.3-5% polymethyl methacrylate or low-TG polymethyl methacrylate, and 1-30% fibres. They may have film coated sides. The manufacturing method comprises the following steps: i) forming a web; ii) impregnating the web with a metasilicate; iii) drying the impregnated web; iv) impregnating the fibrous web with at least one suspension compound comprising said components to form a sheet; (v) cutting the sheet and embedding, or vice versa; (vi) pressing; (vii) the compound in the panel core blank is activated.)

1. Inorganic panels, characterized in that they consist, in dry weight percentage, of 1 to 35% of calcium aluminate, 5 to 40% of kaolin as a first filler, and 10 to 25% of amorphous silicate combined with 5 to 40% of a second inorganic filler.

2. Inorganic panel according to claim 1, characterized in that they consist, in dry weight percentage, of 1-35% of calcium aluminate, 5-15% of kaolin, 10-25% of amorphous silicate, 10-40% of calcium carbonate as second inorganic filler, 1-15% of vegetable fibres, 1-3% of metasilicate, 0.2-2% of aluminium hydroxide, 0.1-0.5% of polycarboxylate and 1-3% of polymethylmethacrylate.

3. Inorganic panel according to claim 2, characterized in that they consist, in dry weight percentage, of 10-30% of calcium aluminate, 7-15% of kaolin, 12-20% of amorphous silicate, 20-40% of calcium carbonate as second inorganic filler, 5-10% of vegetable fibres, 1.5-2.5% of metasilicate, 0.3-1.5% of aluminium hydroxide, 0.2-0.4% of polycarboxylate and 1-3% of polymethylmethacrylate.

4. Inorganic panel according to claim 1, characterized in that they consist, in dry weight percentage, of 1-30% of calcium aluminate, 10-30% of kaolin, 10-25% of amorphous silicate, 5-30% of calcium carbonate, and as second inorganic filler, 5-30% of vegetable fibres, 1-3% of synthetic fibres, 1-2% of metasilicate, 0.2-2% of aluminium hydroxide, 0.1-0.5% of polycarboxylate and 0.3-5% of polymethyl methacrylate with glass transition temperature hardness.

5. Inorganic panel according to claim 4, characterized in that they consist, in dry weight percentage, of 10-25% of calcium aluminate, 15-25% of kaolin, 12-30% of amorphous silicate, 8-25% of calcium carbonate, and as second inorganic filler, 8-25% of vegetable fibres, 2-3% of synthetic fibres, 1-2% of metasilicate, 0.3-1.5% of aluminium hydroxide, 0.2-0.4% of polycarboxylate and 0.3-5% of polymethyl methacrylate with glass transition temperature hardness.

6. Inorganic panel according to claim 1, characterized in that they consist, in dry weight percentage, of 1-30% of calcium aluminate, 15-40% of kaolin, 10-25% of amorphous silicate, 10-35% of technical talc and, as second inorganic filler, 5-20% of a mixture of vegetable fibres, 1-2% of synthetic fibres, 1-3% of metasilicate, 0.2-2% of aluminium hydroxide, 0.1-0.5% of polycarboxylate and 1-4% of polymethyl methacrylate with glass transition temperature hardness.

7. Inorganic panel according to claim 6, characterized in that they consist, in dry weight percentage, of 10-25% of calcium aluminate, 20-38% of kaolin, 12-20% of amorphous silicate, 15-30% of technical talc and as second inorganic filler, 7-15% of a mixture of vegetable fibres, 1-2% of synthetic fibres, 1-2.5% of metasilicate, 0.3-1.5% of aluminium hydroxide, 0.2-0.4% of polycarboxylate and 1-4% of polymethyl methacrylate with glass transition temperature hardness.

8. Inorganic panel according to claim 1, characterized in that their core can have several individual layers, each having a composition according to at least one of claims 2 to 7.

9. The inorganic panels of claim 1, characterized in that they comprise on at least one side a decorative film attached to the core.

10. Inorganic panel according to claim 1, characterized in that their core comprises cork particles.

11. The inorganic panel of claim 1, characterized in that they comprise thermal energy accumulating microspheres in their core.

12. A method for manufacturing a mineral panel according to any one of the preceding claims, characterized in that it comprises the following steps:

i) forming a web;

ii) impregnating the web with metasilicate;

iii) drying the impregnated web;

iv) impregnating the pre-impregnated and dried web with at least one suspension compound comprising, in dry weight percentages, 1-35% calcium aluminate, 5-40% kaolin clay, as a first filler, and 10-25% amorphous silicate in combination with 5-40% second inorganic filler, to form one or more sheets;

v) forming a prefabricated core panel by cutting and embedding or vice versa, the blades being impregnated with the compound indicated in step iii);

vi) forming a blank panel core by pressing the prefabricated panel;

vii) activating the compound in the panel core blank.

13. The manufacturing process according to claim 12, characterized in that prior to step i), a prior metering operation of the various types of fibers, in particular vegetable fibers and/or synthetic fibers, followed by an operation of homogenizing the fiber-blend mixture takes place.

14. The manufacturing process according to claim 12 or 13, characterized in that step i) comprises placing a density of about 16-20g/m on a conveyor belt²And passing it through a roll calender at a temperature of about 120 c at a pressure of about 20-30 bar.

15. The manufacturing process according to at least one of claims 12 to 14, characterized in that step ii) comprises a simple impregnation of the fibrous web with a solution of about 60 to 70% by weight of metasilicate suspended in water, after which impregnation excess water is removed.

16. The manufacturing process according to at least one of claims 12 to 15, characterized in that the impregnation is carried out continuously and that the removal of excess water is carried out continuously also immediately after this impregnation by means of a pair of press rolls.

17. The process according to at least one of claims 12 to 16, characterized in that step iii) consists of drying at a temperature of 120-140 ℃ under ambient pressure.

18. Manufacturing process according to at least one of claims 12 to 17, characterized in that the suspension compound used to impregnate the web in step iv) has the following composition, in dry weight percentages: 1-35% of calcium aluminate, 5-15% of kaolin, 10-25% of amorphous silicate, 10-40% of calcium carbonate as a second inorganic filler, 1-15% of plant fiber, 1-3% of metasilicate, 0.2-2% of aluminum hydroxide, 0.1-0.5% of polycarboxylate and 1-3% of polymethyl methacrylate.

19. The manufacturing process according to claim 18, characterized in that the suspension compound used to impregnate the web in step iv) has the following composition, in dry weight percentages: 10-30% of calcium aluminate, 7-15% of kaolin, 12-20% of amorphous silicate, 20-40% of calcium carbonate as a second inorganic filler, 5-10% of plant fiber, 1.5-2.5% of metasilicate, 0.3-1.5% of aluminum hydroxide, 0.2-0.4% of polycarboxylate and 1-3% of polymethyl methacrylate.

20. Manufacturing process according to at least one of claims 12 to 17, characterized in that the suspension compound used to impregnate the web in step iv) has the following composition, in dry weight percentages: 1-30% of calcium aluminate, 10-30% of kaolin, 10-25% of amorphous silicate, 5-30% of calcium carbonate as a second inorganic filler, 5-30% of vegetable fibers, 1-3% of synthetic fibers, 1-2% of metasilicate, 0.2-2% of aluminum hydroxide, 0.1-0.5% of polycarboxylate and 0.3-5% of polymethyl methacrylate having a glass transition temperature hardness.

21. The manufacturing process according to claim 19, characterized in that the suspension compound used to impregnate the web in step iv) has the following composition, in dry weight percentages: 10-25% of calcium aluminate, 15-25% of kaolin, 12-20% of amorphous silicate, 8-25% of calcium carbonate as a second inorganic filler, 8-25% of vegetable fibers, 2-3% of synthetic fibers, 1-2% of metasilicate, 0.3-1, 5% of aluminum hydroxide, 0.2-0.4% of polycarboxylate and 0.3-5% of polymethyl methacrylate having a glass transition temperature hardness.

22. Manufacturing process according to at least one of claims 12 to 17, characterized in that the suspension compound used to impregnate the web in step iv) has the following composition, in dry weight percentages: 1-30% of calcium aluminate, 15-40% of kaolin, 10-25% of amorphous silicate, 10-35% of industrial talc as a second inorganic filler, 5-20% of a mixture of vegetable fibres, 1-2% of synthetic fibres, 1-3% of metasilicate, 0.2-2% of aluminium hydroxide, 0.1-0.5% of polycarboxylate and 1-4% of polymethyl methacrylate having a glass transition temperature.

23. The manufacturing process according to claim 22, characterized in that the suspension compound used to impregnate the web in step iv) has the following composition, in dry weight percentages: 10-25% of calcium aluminate, 20-38% of kaolin, 12-20% of amorphous silicate, 15-30% of industrial talc as a second inorganic filler, 7-15% of a mixture of vegetable fibres, 1-2% of synthetic fibres, 1-2.5% of metasilicate, 0.3-1.5% of aluminium hydroxide, 0.2-0.4% of polycarboxylate and 1-4% of polymethyl methacrylate having a glass transition temperature.

24. The manufacturing process according to at least one of claims 12 to 23, characterized in that in step iv) the additives added to the composition of the compound used in the process and having a fluidizing and binding function respectively, namely the polycarboxylate and the polymethyl methacrylate or low TG (low glass transition temperature) polymethyl methacrylate, are suspended in water in a proportion of about 55 to 65% by weight, the inerts in liquid form, i.e. metasilicates, as entering the composition of the compound, are suspended in water in a proportion of 30 to 40% by weight, and as additional water, are present in a proportion of at least 40% by weight, relative to the weight of the dry aggregate.

25. Manufacturing process according to at least one of claims 12 to 24, characterized in that in step v) at least one sheet produced in step iv) is cut and subsequently embedded.

26. Manufacturing process according to at least one of claims 12 to 24, characterized in that in step v) at least one sheet produced in step iv) is embedded, in particular embedded by rolling, and subsequently cut.

27. Manufacturing method according to at least one of claims 12 to 26, characterized in that in step vi) a pressure of 50 to 100bar is applied to the panel preform core formed in step v).

28. Manufacturing process according to at least one of claims 12 to 27, characterized in that in step vii), the panel core formed in step vi) is activated in an autoclave at a temperature of 80 to 120 ℃ for 4 to 6 hours at a pressure of 3 to 4bar (vii-1), followed by natural siliconization at ambient temperature and pressure (vii-2) for 10 to 15 days.

29. Manufacturing process according to at least one of claims 12 to 27, characterized in that in step vii), the panel core formed in step vi) is naturally activated with silicon oxide (vii-2) for about 2 months.

30. Manufacturing process according to at least one of claims 12 to 29, characterized in that after step vii) a panel pre-finishing step occurs, which comprises:

a) drying;

b) thickness calibration and adjustment;

c) and (4) applying a primer.

31. The method of claim 30, wherein the drying step a) is performed at a temperature of about 100-120 ℃ and at ambient pressure for a period of about 5-6 hours.

32. The method of manufacturing according to claim 30, characterized in that the primer applied in step c) is an acrylic primer.

33. The manufacturing process according to claim 30, characterized in that the panels are decorated on at least one of their sides with a protective paint or varnish (α -1).

34. The manufacturing process according to claim 30, characterized in that the panels are decorated on at least one of their sides with a decorative film (α -2).

35. Manufacturing process according to claim 33 or 34, characterized in that the panels are subjected to peripheral finishing (β) and packaging.

Technical Field

The present invention relates to non-flammable, mineral-based multifunctional panels free of contaminants, in particular formaldehyde. They are mainly intended for use in the fields of construction, repair, architectural construction and decoration, and industrial applications. The main object of the panel of the present invention is to develop a decorative and supportive panel with high environmental, structural and aesthetic performance requirements. The invention further relates to a method for manufacturing such a panel.

Prior Art

Currently, phenolic based panels, also known as HPL (high pressure laminate) represent the coated panels of the major technology on the market.

Exterior phenolic panels are commonly used as ventilated facade cladding in urban furniture, on balconies and in playground equipment. They can be used indoors in hathouses, more particularly in doors and cabinets.

According to the ISO 4586 and EN 438 standards, High Pressure Laminate (HPL) is defined as a board consisting of a layer of cellulose fibrous material in the form of a sheet impregnated with a thermosetting phenolic resin and bonded by a high pressure process which will result in a density of less than 1.35g/cm and with the simultaneous application of heat³The phenolic panel of (1).

Examples of such laminates are disclosed in U.S. patent 3,616,021 and french patent 2267206.

Briefly, these products consist of a core of kraft paper impregnated with a phenolic resin and an outer layer of decorative paper impregnated with a melamine resin.

Phenolic panels for outdoor applications need to undergo an electron beam curing process, which is a high investment process that impacts the cost of phenolic panels for outdoor applications, which is why few processes employ this technology. Another known treatment for phenolic-based panels for outdoor applications is the application of an acrylic resin topcoat. However, the panels thus produced do not have the same advantageous features as those mentioned at the beginning of this paragraph.

The resins used in the manufacture of phenolic-type panels, which are used for indoor or outdoor applications, contain a contaminant, namely formaldehyde, a substance that is hazardous to health at concentrations that are typically used in these types of panels.

During the manufacturing process, phenolic panels undergo a discontinuous process of high pressure extrusion. This high pressure process consists of the simultaneous application of heat (in the presence of heat)>At a temperature of 120 ℃) and an elevated pressure of (>5MPa, or 50 bar). During this process, chemical crosslinking occurs and the phenolic resin combines with the melamine to form a uniform non-porous compacted panel (having a density of>1.35g/cm³) And the surface thereof has a desired appearance.

In the construction industry, as well as in other technical fields, the internal and external application of HPL laminates is well known. One of the most important characteristics of panels for these applications is their flammability. Flammability was classified according to European standard EN 13501-1. In the case of non-combustible materials, a calorific value of combustion of <3MJ/kg is then required in accordance with ISO 1716.

Current HPL panels with higher flame retardancy use flame retardant synthetic resins (thereby making the final product more expensive). At best, these materials are rated B1 (not readily combustible) according to EN 13501-1. Based on the use of cellulose as carrier material and synthetic resins as binder, it is not possible to achieve a flammability class a (a2 or a1) corresponding to non-flammable products with HPL panels according to the current state of the art.

In contrast, phenolic-type panels have a problem that when contacted with water, as a kraft paper core, upon contact with water during drying and evaporation of the water, uneven tension is generated, causing the panel to warp and delaminate. Another factor that contributes significantly to the premature degradation of such phenolic panels is the orientation of the kraft fiber in the machine direction, which causes the phenolic panels to swell primarily in one direction, in other words, to be non-uniform (produce warpage).

Moreover, the panel has problems caused by its melamine surface. In fact, melamine resins make phenolic panels porous, adsorbing dust, dirt and other types of contamination, causing accelerated deterioration of the panels.

This will affect the color stability, i.e. fading over time.

US 2013/0,323,497 discloses an alternative flame retardant laminate of a2 rating. The laminates disclosed in this invention include various steps and materials used in the manufacture of "conventional HPL" panels, i.e., formaldehyde resins.

Object of the Invention

The object of the present invention is to design multifunctional inorganic panels with various application possibilities in the field of construction, repair, building construction and decoration, including urban or other furniture, as well as industrial applications, in particular decoration and indoor flooring and coverings, without the use of formaldehyde.

Increasingly stringent flame-retardant regulations have significantly limited the field of application of combustible building materials, in particular for exterior applications. Further, advances in building regulatory harmonization require tightening of safety regulations. Architects increasingly demand more robust facade elements with high quality surface finishes (finish). For the indoor field, regulations regarding wall coverings have been tightened in hospitals, nursing homes, schools, public buildings, airports, and especially escape routes. In case of fire, the aim is to ensure a total and safe evacuation of the building, even in case of high evacuation times. The inventive multifunctional panel is intended to allow free design while meeting the safety requirements for such applications, thus achieving a fire resistance rating of a1, and maintaining a high mechanical strength.

Other objects will become apparent upon reading the following description of the invention.

Disclosure of Invention

To this end, the panels according to the invention are characterized in that they consist of 1 to 35% of calcium aluminate, 5 to 40% of kaolin as the first filler, and 10 to 25% of amorphous silicate in combination with 5 to 40% of a second inorganic filler, in percentages by dry weight. It should be noted that kaolin has two functions, either acting as a starting filler or as a plasticizer.

According to a first embodiment of the invention, in which the inorganic panels are rigid panels, these panels consist, in dry weight percentage, of 1 to 35% of calcium aluminate, 5 to 15% of kaolin, 10 to 25% of amorphous silicate, 10 to 40% of calcium carbonate, as second inorganic filler, 1 to 15% of vegetable fibres, 1 to 3% of metasilicate, 0.2 to 2% of aluminium hydroxide, 0.1 to 0.5% of polycarboxylate and 1 to 3% of polymethyl methacrylate. In a preferred embodiment, these panels consist, again in dry weight percentage, of 10 to 30% of calcium aluminate, 7 to 15% of kaolin, 12 to 20% of amorphous silicate, 20 to 40% of calcium carbonate as second inorganic filler, 5 to 10% of vegetable fibres, 1.5 to 2.5% of metasilicate, 0.3 to 1, 5% of aluminium hydroxide, 0.2 to 0.4% of polycarboxylate and 1 to 3% of polymethyl methacrylate.

According to a second embodiment of the invention, in which the mineral panels are flexible panels, these panels consist, in dry weight percentage, of 1 to 30% of calcium aluminate, 10 to 30% of kaolin, 10 to 25% of amorphous silicate, 5 to 30% of calcium carbonate, as a second mineral filler, 5 to 30% of vegetable fibres, 1 to 3% of synthetic fibres, 1 to 2% of metasilicate, 0.2 to 2% of aluminium hydroxide, 0.1 to 0.5% of polycarboxylate and 0.3 to 5% of polymethyl methacrylate of low hardness. In a preferred embodiment, these panels consist, again in dry weight percentage, of 10 to 25% of calcium aluminate, 15 to 25% of kaolin, 12 to 20% of amorphous silicate, 8 to 25% of calcium carbonate, as second inorganic filler, 8 to 25% of vegetable fibres, 2 to 3% of synthetic fibres, 1 to 2% of metasilicate, 0.3 to 1.5% of aluminium hydroxide, 0.2 to 0.4% of polycarboxylate and 0.3 to 5% of polymethyl methacrylate of low viscosity acrylate.

According to a third embodiment of the invention, in which the inorganic panels are memory panels, these panels consist, in dry weight percentage, of 1 to 30% of calcium aluminate, 15 to 40% of kaolin, 10 to 25% of amorphous silicate, 10 to 35% of industrial talc, as a second inorganic filler, 5 to 20% of a blend of vegetable fibres, 1 to 2% of synthetic fibres, 1 to 3% of metasilicate, 0.2 to 2% of aluminium hydroxide, 0.1 to 0.5% of polycarboxylate and 1 to 4% of polymethyl methacrylate of low hardness. In a preferred composition, these panels consist, again in dry weight percentages, of 10 to 25% of calcium aluminate, 20 to 38% of kaolin, 12 to 20% of amorphous silicate, 15 to 30% of technical talc, as a second inorganic filler, 7 to 15% of a blend of vegetable fibres, 1 to 2% of synthetic fibres, 1 to 2.5% of metasilicate, 0.3 to 1.5% of aluminium hydroxide, 0.2 to 0.4% of polycarboxylate and 1 to 4% of polymethyl methacrylate of low viscosity hardness.

A memory panel is to be understood as a flexible panel that bends under an applied load, but does not immediately return to its original position once the load is removed.

Briefly, the three embodiments generally comprise a panel characterized by consisting, in dry weight percent, of 1-35% calcium aluminate, 5-40% kaolin clay as a first filler, 10-25% silicate, 5-40% calcium carbonate or a second inorganic filler of industrial talc, 1-3% metasilicate, 0.2-2% aluminum hydroxide, 0.1-0.5% polycarboxylate, 0.3-5% polymethyl methacrylate or low-TG polymethyl methacrylate, and 1-30% fiber.

According to a preferred embodiment, and in addition to the components described above, and in addition to the aforementioned polycarboxylates and polymethylmethacrylate, a very small percentage of wetting agents, pH adjusters and pigments can also be used as additives.

According to the invention, as mentioned above, about 96% of the dry weight of the product consists of natural raw materials.

Another natural raw material that can be added to the panel composition of the present invention is cork particles preferably having an average diameter of 0.5-5mm and 3-10% dry weight.

As additives, it is also possible to use from 5 to 15% by weight of the heat energy accumulating microspheres.

According to the invention, the inorganic panels may combine the features of the three embodiments described above, in any combination, and in several layers, within the same core. Thus, for example, a panel according to the invention may have a rigid intermediate layer and two flexible layers, another example being a panel with a core consisting of a rigid intermediate layer, a flexible surface layer and another memory surface layer. Obviously, this combination can have more than three layers in the same core.

The invention further relates to a process for manufacturing the panel described above.

This method comprises the steps of:

-an initial step of forming a web;

-a second step consisting of impregnating the fibrous web with metasilicate and drying it;

-a third step comprising drying the impregnated fibrous web;

-a fourth step consisting of: impregnating the web pre-impregnated and dried beforehand in the preceding step with at least one suspension compound according to the invention, i.e. by incorporating, on a dry weight basis, 1 to 35% of calcium aluminate, 5 to 40% of kaolin, as the first filler, and 10 to 25% of amorphous silicate in combination with 5 to 40% of the second inorganic filler, to form one or more sheets obtained;

-a fifth step consisting of: forming panel preform cores by cutting and embedding sheets impregnated with the compound of the invention, or vice versa;

-a sixth step consisting of pressing the prefabricated panels, forming panel core blanks;

-a seventh step consisting of activating the compound in the panel core blank.

According to the process of the invention, depending on whether the sheet is intended to represent a rigid product, a flexible product or a memory product, a suspension compound is used in step iv), the composition of which, in dry weight percentages, is as described above for the first to third embodiments, respectively.

It should be noted that in the three embodiments described above, the synthetic additives added in the composition of the compound used in step iv) and each having the function of fluidization and binding agent, i.e. the polycarboxylate and the polymethyl methacrylate or low-TG (low glass transition temperature) polymethyl methacrylate, are suspended in water at about 55 to 65% by weight. The liquid form of the inerts added to the composition of the compound, i.e. metasilicates, was suspended in water at 30 to 40% by weight. Additional water is used in a proportion of at least 40% by weight with respect to the mass of dry inerts, so that the compound remains in suspension.

According to the invention, one or more sheets are subjected to cutting followed by embedding, i.e. embedding in particular by winding followed by cutting, whereupon a panel preform core is formed, which is subjected to a pressure of about 50 to 100bar, in particular in a press, thereby forming a panel core blank.

The panel core is activated, preferably in an autoclave, followed by a natural siliconization step. Alternatively, both activation and silicidation may naturally occur in longer steps. Alternatively, siliconization in an autoclave may be arranged, however, this would require the addition of an unnatural (unnatural) accelerator to the web impregnation compound used in step iv).

The finishing of the panel starts with a pre-finishing step in which the panel blank core is exposed to the following three steps: a) drying; b) calibrating and adjusting the thickness; and c) applying a primer to the surface.

On their side surfaces the panel cores are either surface varnished, or impregnated decorative films are applied, or finally surface finished. The panels thus formed are finally subjected to peripheral fine finishing and packaged.

According to one embodiment of the invention, immediately after its siliconizing process to consolidation, the panel core blank mentioned above undergoes drying, followed by calibration, and initial application of a primer, and finally painting or protective varnish, or in the latter case decorative surface film, is the application of its glue product on the surface of said primer.

Advantages of the Panel according to the invention

The panels according to the invention are distinguished from phenolic panels by their non-flammability (a1 rating) because they are free of contaminants, in particular formaldehyde, have high dimensional stability and high moisture resistance, and by a decorative surface which withstands various environmental conditions and allows various modifications. In addition to being highly durable and recyclable, panels according to the invention are also weather resistant, frost and thaw resistant, impact resistant and antimicrobial. As a result of these properties, these panels can be safely used in most different applications, for example applications in which it is not possible to use phenolic panels, in particular because of their flammability.

Another important advantage of the present invention over phenolic panels is their manufacturing process, which involves lower energy consumption and does not use environmentally harmful raw materials.

In addition, all the waste materials generated during the manufacturing process, in particular the excess water in the aforementioned second (ii) and fourth (iv) steps, as well as the sheet remnants resulting from the final trimming, are reintroduced into the process itself, and the cuttings are completely recovered after grinding, thus making the manufacturing process of the invention environmentally friendly.

Other advantages will become apparent upon reading the present specification.

Drawings

The drawings are merely schematic and presented by way of example and not limitation, showing an example of a panel according to a particular exemplary embodiment of the present invention, whose dimensions and proportions are not necessarily the actual dimensions and proportions, but are intended merely to represent the principle aspects of the invention, the scope of which is determined by the claims appended hereto.

[ FIG. 1]

Fig. 1 illustrates a panel core according to the present invention.

[ FIG. 2]

Fig. 2 illustrates a panel core according to the present invention, in particular an embodiment in which cork or another sound insulating material is used.

[ FIG. 3]

Fig. 3 illustrates a panel according to the present invention, in particular an embodiment wherein the central core is surface covered on each side with an impregnated decorative film.

[ FIG. 4]

Fig. 4 illustrates a panel according to the present invention, in particular an embodiment wherein the central core is surface covered on each side with impregnated decorative aluminium foil.

[ FIG. 5]

[ FIG. 6]

Fig. 5, 6 illustrate panels according to the invention in rigid and flexible configurations, respectively.

[ FIG. 7]

Fig. 7 illustrates a panel according to the invention in a "memory" configuration found in its natural position, i.e. it is not affected by external forces, as shown by the dotted lines.

[ FIG. 8]

[ FIG. 9]

[ FIG. 10]

Figures 8, 9 and 10 illustrate panels according to the invention having a core with three separate main layers, namely flexible/rigid/flexible, rigid/flexible/rigid and "memory"/rigid, respectively.

[ FIG. 11]

FIG. 11 is an exemplary schematic illustration of the first step of the panel making process according to the present invention, i.e., the formation of a web.

[ FIG. 12]

Fig. 12 is an exemplary schematic diagram of the second and third steps of the panel manufacturing method according to the present invention, i.e., the first impregnation and subsequent drying of the web.

[ FIG. 13]

Fig. 13 is an exemplary illustration of the fourth step of the panel manufacturing method according to the invention, i.e. the second impregnation of the web, thus forming a sheet, and two variants of the fifth step of the method, i.e. cutting and embedding the sheet separately, or embedding by winding the sheet, including cutting.

[ FIG. 14]

Fig. 14 is an exemplary schematic illustration of the sixth step of the panel manufacturing method according to the invention, i.e. the pressing of the preform core of the panel, and a part of the seventh step of the method, i.e. the autoclave activation.

[ FIG. 15]

Fig. 15 is an exemplary schematic view of the second part of the sixth step of the panel manufacturing method according to the present invention, i.e., natural silicidation, and the first step of the panel pre-modification process.

[ FIG. 16]

Fig. 16 is an exemplary schematic representation of the second and third steps of the panel pre-finishing process, i.e. calibration and adjustment of its thickness, and the primer application, respectively, and the two variants of the first step of the final panel finishing, i.e. the application of the protective paint or varnish, and the application of the impregnated decorative film, respectively, according to the present invention.

[ FIG. 17]

FIG. 17 is an exemplary schematic diagram of the trimming operation, i.e., the completion of the peripheral fine trimming and packaging operations.

Detailed Description

Exemplary embodiments of the present invention are described below with reference to the accompanying drawings, where the reference numerals are as follows, as appropriate.

[ Table 1]

1		Panel core
				11	Rigid layer
	12	Flexible layer
				13	Memory layer
2		Cork wood
			3		Impregnated decorative film
4		Decorative aluminum foil
500		Fiber
			501		Fiber web
502		Fiber net roll
			503		Dry impregnated fibrous web roll
504		Composite impregnated fibrous web sheet
			505		Panel prefabricated core
506		Panel core blank

According to an exemplary embodiment, the panel manufacturing process includes a first step (i) of forming a web (501) of fibers (500) as shown in FIG. 11, wherein the fibers are provided on a conveyor belt at a density of about 16-20g/m²Is deposited and passed through a roll calender (701) at a pressure of about 20-30bar and a temperature of about 120 c, thereby forming a web that can be rolled on a roll (502). The fibers are selected prior to the previously described application of the fiber layer. Preferably, the fibres used are selected from plant fibres, either of one single type or more than one type depending on the type of product to be produced. Also, synthetic fibers may be used. If the fibers are not a single type of fiber, they are metered followed by a blending operation to obtain a uniform distribution as part of the foregoing application.

In a second process step (ii), as shown in fig. 12, the web is impregnated, preferably continuously impregnated, with a solution of about 60 to 70% by weight of a metasilicate suspended in water for a short period of time, excess moisture being removed, for example, by means of a pair of press rolls (not shown in the drawing), whereupon, as shown in fig. 12, the web so impregnated is subjected to a third step (iii), i.e. a drying process at a temperature of 120 ℃. at 140 ℃ under ambient pressure in a dryer, whereupon the impregnated and dried fabric can be rewound, as in particular on roll (503).

The impregnation can be carried out by any prior art method, such as continuous immersion in a vat (e.g., a vat having a length of less than 1 meter and circulating the web at a speed of about 100 m/min), passing it between transfer rolls, or by spraying.

Said impregnation of the fibrous web acts as a waterproofing of the fibres, so that they retain their mechanical properties, thus avoiding their natural biological deterioration processes, making them completely inert, and increasing their flame-retardant capacity. In addition, it promotes adhesion to the fibrous web of the compound to be subsequently impregnated.

In a fourth step (iv), as shown in fig. 13, the web, which has been impregnated and dried, is impregnated with a compound according to the invention, said compound preferably being formed by the following steps: in a dry mixer (702), its inerts and the respective mixtures are metered, and they are then mixed in a second mixer (703) with metered amounts of liquid components, namely liquid silicates (metasilicates suspended in water at 30 to 40% by weight) and additives (i.e. polycarboxylates and polymethylmethacrylate suspended in water at 55 to 65% by weight), and additional water in a proportion of at least 40% by weight, relative to the dry inerts, in order to maintain the resulting compound in suspension.

This impregnation (iv) step of pre-impregnating the web with the silicate with the compound is preferably carried out in a curtain (curve) system, preferably on a microperforated conveyor, and is preferably evacuated at its lower end portion in order to remove excess water and assist in pulling the web on the conveyor. Preferably, the thickness of the sheet (504) so formed is about 0.8-1.2 mm. The curtain system is multiple and makes it possible to apply the different compounds of the invention in order to form the desired panels as described above, so that at each moment the sheet formed has a composition suitable for the panel, and a portion of the panel if applicable, to be introduced.

In a fifth step (v), a panel preform core (505) is formed from the sheet (504) formed in the previous step, which can be carried out in particular by any of the following two variants (v-1; v-2) of the method (these variants are shown in fig. 13):

-cutting the sheet (504) into portions of desired length for the panels, each portion being deposited on top of the previous cut portion until the number of sheet portions required for forming the panels is reached, and according to the thus assembled aggregate (collection), called panel preform core (505) for the press;

-a forming roll having a circumference equal to the maximum length of each panel continuously winds the sheet (504) providing a number of windings corresponding to the number of required sheet layers of the panel core, thus constituting a wound and cut panel preform core (505), and is stripped from the forming roll and advanced into the press.

In a sixth step (vi), each panel preform core (505) is pressed at a pressure of 50-100bar for about 15 to 20 seconds, as shown in fig. 14. Pressing allows the air within the panel structure to be removed and further compresses the panels, causing them to become high density. According to embodiments of the present invention, panels of greater than 3,700 x 1,650mm and 6 to 20mm thickness can be obtained. Embedding without wrapping, even higher thicknesses are technically achievable.

Although, as mentioned above, this panel thickness is obtained gradually during the core production process, it is certain that at the end of the pressing the sheets are inevitably joined to each other, so as to obtain at least 1,500kg/m³The density of (c). Furthermore, it is interesting to note that they already have sufficient strength, after embedding and before pressing, to be handled by machines or manually, due to the composition characteristics of the sheets.

As said fig. 14 shows, the already pressed core blanks (506) are stacked and transferred to an autoclave, where in a seventh step (vii-1) of activating the additives they are exposed to a temperature of about 80-120 ℃ for a period of 4-6 hours at a pressure of about 3-4bar, so that the panels get a relative humidity of 30-50%. As shown in fig. 15, the eighth step (vii-2) is followed, in which the panel preform core is subjected to a natural siliconizing process at ambient temperature for about 10-15 days. Also in the ninth step (a) shown in fig. 15, the panel core having a relative humidity of about 20-30% is subjected to a drying process at ambient pressure and at a temperature of about 100-120 ℃ for about 5-6 hours in a dryer, resulting in a relative humidity of about 1-2%. In a tenth step (b), the panel core is individually dimensioned to the desired thickness, whereupon in a tenth step (c) a methacrylate-based primer is applied on the surface.

In a twelfth step, the primed core is provided with a decorative surface finish solely by one of the following two methods (α -1; α -2), which are shown in FIG. 16:

-applying (α -1) a protective paint or varnish (609) to each panel core on each of its two surfaces. In particular, polyester resins or acrylic resins can be used as varnishes, and water-based paints can be used as paints.

-applying heat (α -2) of [ chemical ] reactive product on at least one side to each panel core for bonding with the primer and the decorative surface film (3), applying pressure of about 2-3bar in a roller mill (706). The reactive product of the heat bonding of the surface film is preferably selected from the group consisting of polyurethanes, polyesters, epoxies and polyethers. The decorative film may be, for example, a paper sheet impregnated with synthetic resin, a metal sheet, i.e., an aluminum, copper or stainless steel sheet, or a polymer, e.g., a Polyester (PES), polyethylene terephthalate (PET) or polyvinyl chloride (PVC) film. The decorative film may have a uniform color, or may have an image (imaginative), with any basic or decorative pattern, such as a simulated wood or natural stone.

In a thirteenth step (β), each panel is trimmed to the desired final size for use or packaging, as shown in fig. 17.

The method according to the invention has the advantage of energy saving.

Fig. 1-10 show several examples of any panel or such panel core according to the invention. For sheets/cores of different stiffness, the core can be colored by avoiding pigments, e.g., using different colors. The cross-sectional view of the panel will thus identify its type.

The panels according to the invention have high chemical resistance, including resistance to UV rays, scratch and impact.

Furthermore, in the foregoing case of using cork in the panel core, according to certain specific embodiments, the panel has certain beneficial characteristics of reinforcement, such as heat resistance.

If energy storage microspheres are used in the panel core as described above, these can be used as heat accumulators, releasing the heat absorbed during the day at night.

Other special applications may include, for example, in the case of decorative aluminium foils, the use of aluminium foils, in particular aluminium foils treated with:

silver ions which interfere with the growth of microbial colonies, so that panels with such foils can be used in environments where cleaning and hygiene are a priority. Typical fields of application are indoor environments, hospital centers, health centers, schools, baby rooms, changing rooms, air conditioning systems.

Paints with special high performance and high quality pigments that significantly improve the reflection level of dark shades and significantly reduce the surface temperature. A typical field of application is the external environment as facade cladding and ventilated facades, which in particular have a high solar exposure.

It should be noted that as described above and as set forth in the claims, various modifications or changes may be made to the specific embodiments of the invention described herein without departing from the spirit and scope of the invention.