CN120481402A - 制造建筑构件的方法和建筑构件 - Google Patents

制造建筑构件的方法和建筑构件

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Publication number
CN120481402A
CN120481402A CN202510281086.8A CN202510281086A CN120481402A CN 120481402 A CN120481402 A CN 120481402A CN 202510281086 A CN202510281086 A CN 202510281086A CN 120481402 A CN120481402 A CN 120481402A
Authority
CN
China
Prior art keywords
particles
layer
mixture
pigment
cohesive
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
CN202510281086.8A
Other languages
English (en)
Inventor
A·赫德伦
S·尼尔森
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
Publication of CN120481402A publication Critical patent/CN120481402A/zh
Pending legal-status Critical Current

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Classifications

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Abstract

本公开涉及一种制造建筑构件(10)的方法，其包括在基底(2)的第一表面上施加第一层(1)，所述第一层(1)包括粘合剂、至少一种填料和精细非颜料内聚粒子的混合物，其中所述混合物中的精细非颜料内聚粒子的量可为所述混合物的0.05重量％至9重量％，和对第一层(1)和/或基底(2)施加热和/或压力，由此形成建筑构件(10)。本公开进一步涉及这样的建筑构件(10)。

Description

制造建筑构件的方法和建筑构件
本申请是申请日为2020年1月9日、申请号为202080007885.1、国际申请号为PCT/SE2020/050010的名称为“制造建筑构件的方法和建筑构件”的中国发明专利申请的分案申请。
技术领域
本发明的实施方案涉及一种制造建筑构件的方法和建筑构件。
技术背景
具有木质表面的地板覆盖物可能有几种不同类型。实木地板由厚板形式的实心木板形成。实木复合地板(Engineered wood flooring)由胶粘到芯层上的木材表面层形成。芯层可以是薄片芯(lamella core)或木基板(wood-based panel)，如胶合板、MDF或HDF。作为一个实例，木质表面层可具有2-10mm的厚度。
木质地板覆盖物也可通过将木单板(wood veneer)胶粘到基底，例如木基板，如刨花板、MDF或HDF上形成。木单板是薄木层，例如具有0.2-1mm的厚度。具有胶粘到例如HDF或胶合板的芯层上的独立表面层的地板比实木地板更耐湿。
与实木地板和实木复合地板相比，木单板地板(wood veneer floorings)可以更低成本生产，因为仅使用薄木层。
最近已开发出具有包含木粒子、粘合剂和耐磨粒子的基本均匀混合物的实心表面的新型地板。这样的地板和建筑面板以商标出售。
根据将包含木粉、粘合剂如三聚氰胺甲醛和任选地，耐磨粒子的混合物以粉末形式施加在芯层上的生产方法生产该面板。在WO 2009/065769中公开了这样的方法。在US2012/0263878中公开了控制这种方法中的固化损失的方法。
将该混合物以干粉形式铺散(scatter)在木质芯层，例如HDF上。已经表明木粉在低应力环境(如从大袋中排出、空气输送和铺散)中具有相当低的可流动性。例如，难以将木粉均匀铺散在基底上而不获得无木粉的裸露区域、具有较少粉末的区域或施加了太多粉末的区域。原因在于木粉在低应力过程中成桥(bridge building)和成洞(ratholing)。成洞是指仅排空料斗或料仓中心的材料，因此留下周边材料。
这两种行为归因于粒子质地(texture)、形状和密度，就木粉而言都因此提高机械联锁、成桥或成洞的风险。木粉粒子或纤维粗糙，具有扭结和原纤，成纤维状并因此远非球形，并且该粒子不够致密以致无法引发破坏桥的重力。
作为该混合物的另一主要组分的粘合剂通常包含至少与木粉相比更自由流动的粒子。
在已将该混合物施加在芯层上后，该混合物随后在热和压力下固化成布置在芯层上的0.1-1.0mm厚的表面层。当固化三聚氰胺甲醛树脂时，三聚氰胺甲醛树脂的收缩在该层中引起张力。在该层中形成的内应力可能造成面板的翘曲。必须通过在面板背面的反张力补偿在面板正面的张力。因此，通常在与该层相反的芯层的背面布置平衡层。平衡层适于平衡由压制、冷却和气候变化造成的收缩和膨胀。平衡层可以是树脂浸渍纸或由包含木粉和热固性粘合剂的混合物形成的粉末。
US2005/0250879涉及通过使粉末涂布粒子熔融或流动成内聚层、接着使组分固化以形成连续膜而形成的粉末涂膜。粉末组合物包含在原料混合物(raw mix)中的作为具有1至25μm的平均粒度的未结合离散粒子的成分混合物。该原料混合物包含一种成膜(共)聚合物或树脂。
概述
本发明的至少一些实施方案的一个目的是提供相对于上述技术和已知技术的改进。
本发明的至少一些实施方案的另一目的是优化生产建筑构件的方法。
本发明的至少一些实施方案的另一目的是使该方法更有成本效益，并因此在保持良好品质的同时降低建筑构件的成本。
本发明的至少一些实施方案的另一目的是施加具有均匀厚度的层。
本发明的至少一些实施方案的另一目的是改进建筑构件的形状。
通过下文公开的至少一些方面实现从说明书中显而易见的这些和其它目的和优点的至少一些。
在第一方面中，公开了一种制造建筑构件的方法，其包含在基底的第一表面上施加第一层，所述第一层包含粘合剂、至少一种填料和内聚粒子(cohesive particle)的混合物，和对第一层和/或基底施加热和/或压力，由此形成建筑构件。
内聚粒子可以是精细内聚粒子。精细粒子可被定义为至少70％的粒子具有2.5μm或更小的在其最大维度中的长度，如0.1μm至2.5μm的在其最大维度中的长度。
该混合物中的内聚粒子的量可在0.05重量％至9重量％之间。
内聚粒子可以是非颜料内聚粒子。非颜料内聚粒子可意味着粒子不是常规颜料，如钛颜料、炭黑、氧化铁颜料、铜颜料等。常规使用的钛颜料的一个实例是二氧化钛。非颜料内聚粒子可以是具有低的由于波长选择性吸收而改变反射光或透射光的颜色的能力的粒子。因此，内聚粒子在该工业中照惯例不在颜料的意义上使用。常规颜料可具有小于500nm的尺寸。反射颜料，如白色颜料具有比吸收颜料大的尺寸(如300-400nm)。
内聚粒子可以是精细非颜料内聚粒子。
应该理解的是，内聚粒子是具有内聚吸引力或内聚力的粒子。内聚力是粒子粘在一起、相互吸引的作用或性质或诸如此类。这是由至少一个粒子的形状和结构造成的物质的固有性质，以形成可保持微观结构的电吸引力。换言之，内聚能够通过为粒子表面分子创造类似堆积体的环境(bulk-like atmosphere)来降低表面能。
第一方面的一个优点在于精细内聚粒子由于它们的内聚性质而倾向于涂布填料，如木粉，包括木纤维或木粒子，以填充空洞、孔隙、扭结和原纤。由此，内聚粒子使得木粒子更光滑和更不容易发生机械联锁。因此，至少降低如上文解释的桥接(bridging)和/或成洞的风险。
当减少桥接和/或成洞时，至少降低在基底上不均匀施加该混合物的风险。由此，第一层可在其整个延展度上具有均匀厚度。均匀厚度在美学上理想，而且归因于第一层的平衡。如果第一层具有均匀厚度，将降低平衡层对抗在固化过程中和/或之后由第一层形成的力所需的力。由此可减少平衡层中的粘合剂的量。
由于它们的高内聚行为，内聚粒子通常表现出不佳的流动性。填料，如木粉由于高机械联锁风险而表现出不佳的流动性。但是，已经令人惊讶地发现和在本文中显示，通过该混合物中的内聚粒子的特定浓度，可平衡这两种不同性质以令人惊讶地提高可流动性。如果该混合物中的内聚粒子的量太低，木粉的机械联锁性质将占优势，以造成低流动性。如果该混合物中的内聚粒子的量太高，内聚粒子的内聚性质将占优势，以造成低流动性。应该平衡内聚粒子的量以改进可流动性。该混合物中的精细非颜料内聚粒子的量可以为混合物的0.05重量％至9重量％。
一个优点在于热和/或压力处理过的第一层在其整个延展度上，优选在其纵向和横向延展度上具有基本相同的厚度。
提高的可流动性的一个优点在于该混合物更均匀分布在基底上。
所述内聚粒子，如精细非颜料内聚粒子的内聚力(cohesion force)可能超过所述至少一种填料的内聚力(cohesive force)。由此，内聚粒子倾向于涂布填料。
如用标准Shear Cell Program，50mm shear 6kPa(FT4 Powder Rheometer)测得的所述内聚粒子，如精细非颜料内聚粒子的内聚力可为至少0.25kPa，如0.25至3kPa。标准Shear Cell Program是Freeman Technology FT4 Powder Rheometer用的标准程序。当使用木粉作为填料时，用所述标准Shear Cell Program测量时测得包含木纤维的木粉的内聚力为0.25kPa。
该混合物可以干燥形式提供。
该混合物可以干燥形式施加在基底上。
该混合物可以是干粉。
该混合物中的内聚粒子，如精细非颜料内聚粒子的量可在0.2重量％至4.5重量％之间。
该混合物中的内聚粒子，如精细非颜料内聚粒子的量可在0.5重量％至5重量％之间，如在2重量％至4重量％之间。
至少70％的内聚粒子，如精细非颜料内聚粒子可具有2.5μm或更小的在其最大维度中的长度，优选0.1μm至2.5μm的在其最大维度中的长度。
内聚粒子，如精细非颜料内聚粒子可具有2.5μm或更小的在其最大维度中的长度，优选0.1μm至2.5μm的在其最大维度中的长度。
内聚粒子，如精细非颜料内聚粒子可具有小于1.9的折射率(RI)。
内聚粒子，如精细非颜料内聚粒子可选自硅酸盐，如硅酸铝或硅氧化物，如SiO2。
SiO2可作为气相二氧化硅(fumed silica)提供。
内聚粒子，如精细非颜料内聚粒子可以是碳酸钙。
内聚粒子，如精细非颜料内聚粒子可以是硫酸钡。
内聚粒子，如精细非颜料内聚粒子可以是polytetrafluoreten。
所述至少一种填料可以是或包含纤维。
所述至少一种填料可包含木粉。木粉可包含木纤维或木粒子。木纤维粒度可以是0-300μm，如0-150μm。木纤维粒度可以是10-300μm，如10-150μm。
粘合剂可以是热固性粘合剂或热塑性粘合剂。
粘合剂可以是脲甲醛树脂、包含脲甲醛树脂的混合物或包含脲甲醛树脂的共聚物、苯酚甲醛树脂、包含苯酚甲醛树脂的混合物或包含苯酚甲醛树脂的共聚物、三聚氰胺甲醛树脂、包含三聚氰胺甲醛树脂的混合物或包含三聚氰胺甲醛树脂的共聚物，或它们的混合物。
第一层可进一步包含耐磨粒子。
第一层可进一步包含颜料粒子。
基底可选自木质板(wood-based board)、刨花板、热塑板、胶合板、薄片芯、单板层(veneer layer)。
第一层可永久附着于基底，由此形成建筑面板。
建筑面板可以是地板或墙板。
该方法可进一步包含在第一层上施加表面层作为第二层。
该方法可进一步包含在基底的第二表面上施加平衡层，第二表面与基底的第一表面相反。
在第二方面中，提供一种建筑构件。所述建筑构件包含布置在基底上的第一层，所述第一层由包含粘合剂、至少一种填料和内聚粒子的混合物形成，其中通过施加热和/或压力形成所述建筑构件。
可通过施加热和/或压力固化所述建筑构件。
内聚粒子可以是精细内聚粒子。精细粒子可被定义为至少70％的粒子具有2.5μm或更小的在其最大维度中的长度，如0.1μm至2.5μm的在其最大维度中的长度。
该混合物中的内聚粒子的量可在0.05重量％至9重量％之间。
内聚粒子可以是非颜料内聚粒子。非颜料内聚粒子可意味着粒子不是常规颜料，如钛颜料、炭黑、氧化铁颜料、铜颜料等。常规使用的钛颜料的一个实例是二氧化钛。非颜料内聚粒子可以是具有低的由于波长选择性吸收而改变反射光、吸收光或透射光的颜色的能力的粒子。因此，内聚粒子在该工业中照惯例不在颜料的意义上使用。常规颜料可具有小于500nm的尺寸。反射颜料，如白色颜料具有比吸收颜料大的尺寸(如300-400nm)。
内聚粒子可以是精细非颜料内聚粒子。
应该理解的是，内聚粒子是具有内聚吸引力或内聚力的粒子。内聚力是粒子粘在一起、相互吸引的作用或性质或诸如此类。这是由至少一个粒子的形状和结构造成的物质的固有性质，以形成可保持微观结构的电吸引力。换言之，内聚能够通过为粒子表面分子创造类似堆积体的环境来降低表面能。
第二方面包含先前已论述的第一方面的所有优点，由此先前的论述也适用于建筑构件。
所述内聚粒子，如精细非颜料内聚粒子的内聚力可能超过所述至少填料的内聚力。
如用标准Shear Cell Program，50mm shear 6kPa(FT4 Powder Rheometer)测得的所述内聚粒子，如精细非颜料内聚粒子的内聚力可为至少0.25kPa，如0.25至3kPa。标准Shear Cell Program是Freeman Technology FT4 Powder Rheometer用的标准程序。
该混合物可以干燥形式提供。
该混合物可以干燥形式施加在基底上。
该混合物可以是干粉。
该混合物中的内聚粒子，如精细非颜料内聚粒子的量可在0.2重量％至4.5重量％之间。
该混合物中的内聚粒子，如精细非颜料内聚粒子的量可在0.5重量％至5重量％之间，如在2重量％至4重量％之间。
至少70％的内聚粒子，如精细非颜料内聚粒子可具有2.5μm或更小的在其最大维度中的长度，优选0.1μm至2.5μm的在其最大维度中的长度。
内聚粒子，如精细非颜料内聚粒子可具有2.5μm或更小的在其最大维度中的长度，优选0.1μm至2.5μm的在其最大维度中的长度。
内聚粒子，如精细非颜料内聚粒子可具有小于1.9的折射率(RI)。
内聚粒子，如精细非颜料内聚粒子可选自硅酸盐，如硅酸铝或硅氧化物，如SiO2。
SiO2可作为气相二氧化硅提供。
内聚粒子，如精细非颜料内聚粒子可以是碳酸钙。
内聚粒子，如精细非颜料内聚粒子可以是硫酸钡。
内聚粒子，如精细非颜料内聚粒子可以是polytetrafluoreten。
所述至少一种填料可包含木粉。木粉可包含木纤维或木粒子。
粘合剂可以是热固性粘合剂或热塑性粘合剂。
粘合剂可以是脲甲醛树脂、包含脲甲醛树脂的混合物或包含脲甲醛树脂的共聚物、苯酚甲醛树脂、包含苯酚甲醛树脂的混合物或包含苯酚甲醛树脂的共聚物、三聚氰胺甲醛树脂、包含三聚氰胺甲醛树脂的混合物或包含三聚氰胺甲醛树脂的共聚物，或它们的混合物。
第一层可进一步包含耐磨粒子。
第一层可进一步包含颜料粒子。
基底可选自木质板、刨花板、热塑板、胶合板、薄片芯、单板层。
第一层可永久附着于基底，由此形成建筑面板。
建筑面板可以是地板或墙板。
建筑面板可进一步包含在第一层上的表面层作为第二层。
建筑面板可进一步包含布置在基底的第二表面上的平衡层，第二表面与基底的第一表面相反。
附图简述
参照显示本发明的实施方案的所附示意图更详细举例描述本发明的实施方案。
图1A显示一种生产建筑构件的方法。
图1B显示建筑构件的一个实施方案。
图1C显示建筑构件的一个实施方案。
图1D显示建筑构件的一个实施方案。
图2A显示参考粉末组合物。
图2B显示根据本发明的一个实施方案的示例性粉末组合物。
图3A显示实施例1中的样品A和样品F的自由落体实验的结果。
图3B显示实施例2中的样品A和样品F的铺散实验的结果。
图4A显示与参考样品相比所选的精细非颜料内聚粒子的渗透率结果。
图4B显示取决于以Mikhart为代表的碳酸钙的浓度的渗透率结果。
图4C显示取决于以Polygloss为代表的精细高亮度硅酸铝的浓度的渗透率结果。
详述
在本文中公开了一种制造建筑构件10的方法，其包含在基底2的第一表面上施加第一层1，第一层1包含粘合剂、至少一种填料和内聚粒子4的混合物，对第一层和/或基底施加热和/或压力，由此形成建筑构件10。
现在参考图1A-D描述制造建筑构件10的方法和由此形成的建筑构件10。
建筑构件10可以是建筑面板，如地板、天花板、墙板、门板、操作台面、家具部件或家具部件的一部分、踢脚板、模制品、镶边型材等。
该方法包含提供基底2。基底优选是在制造建筑构件10的方法前制成的预制基底。基底可包含至少一个木单板层。基底可包含几个木单板层，如作为胶合板。优选地，贴面构件(veneered element)包括奇数的木单板层。基底可包含木基板。木基板可选自HDF、MDF、OSB、薄片芯和实木。基底可以是热塑板。基底可包含热塑性材料。基底可以是矿物复合板。基底可以是纤维水泥板。基底可包含片材，如纸张或无纺材料的片材或传送带(conveyor)。基底优选是在制造建筑构件10的方法前制成的预制基底。木质基底可以是基于木纤维的板，如MDF、HDF、刨花板或胶合板。基底可以是木塑复合材料(Wood Plastic Composite)(WPC)。基底可以是矿物复合板。基底可以是氧化镁水泥板。基底可以是陶瓷板。基底可以是塑料板，如热塑板。
基底2可以是载体，如纸张、无纺片材或木单板。
当第一层1永久附着于基底2时，建筑构件10是建筑面板。永久意味着在通过施加热和/或压力使它们附着于基底后，基底无法与至少第一层分离。
当基底是临时载体，如纸张或无纺片材或传送带时，第一层可逆附着于基底10。可逆意味着在施加热和/或压力后，至少第一层1可与基底2分离。
基底2具有两个表面。第一表面面向第一层1。第二表面是与第一表面相反的基底2的表面。如果任选向基底施加平衡层5，基底2的第二表面面向平衡层5。
根据另一方面，该方法进一步包含在基底2的第二表面上施加平衡层5，第二表面与基底2的第一表面相反。
平衡层5可以是作为粉末施加的粉末基平衡层。粉末基平衡层可包含木粒子，如木质纤维素和/或纤维素粒子和粘合剂，优选热固性粘合剂，如氨基树脂。平衡层可以是树脂浸渍的纸，优选被热固性粘合剂浸渍。平衡层可具有与第一层1相同的组成。
在基底2的第一表面上施加第一层1。可如图1A中所示通过铺散施加第一层1。
第一层1由包含粘合剂、至少一种填料和内聚粒子的混合物形成。
该混合物以干燥形式施加。该混合物优选以干粉形式施加。
所述至少一种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。木粒子可以是木质纤维素粒子和/或纤维素粒子。木粒子可至少部分漂白或具有原木色。粒子也可在将它们添加到混合物中之前着色。填料可以是稻米、秸秆、玉米、黄麻、亚麻(linen、flax)、棉、麻(hemp)、竹粒子或纤维。填料可以是金属、陶瓷填料、复合填料等；例如硅酸盐或硅氧化物(silicone oxide)。
下面将使用粒子和纤维作为替代。
在混合物中可能存在多于一种填料。该混合物可包含两种或更多种上文论述的填料的组合。
粘合剂可以是热固性或热塑性粘合剂。
第一层1可包含热固性粘合剂。热固性粘合剂可以是氨基树脂，如三聚氰胺甲醛、脲甲醛或其组合。热固性粘合剂可以是苯酚甲醛。
第一层1可包含热塑性粘合剂。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。热塑性粘合剂同时将基底2的第一表面粘合到第一层1。
根据另一方面，第一层1可包含脲甲醛树脂、包含脲甲醛树脂的混合物或包含脲甲醛树脂的共聚物、苯酚甲醛树脂、包含苯酚甲醛树脂的混合物或包含苯酚甲醛树脂的共聚物、三聚氰胺甲醛树脂、包含三聚氰胺甲醛树脂的混合物或包含三聚氰胺甲醛树脂的共聚物或它们的混合物作为热固性粘合剂。
该混合物可进一步包含内聚粒子，如精细非颜料内聚粒子。
粒子是具有离散物质量并具有相对于周围环境的表面的粉末组分，意味着单个离散组分或通过偶联剂化学或物理结合在一起以形成更大质量和/或尺寸的一个实体单元的两个或更多个这样的组分。
内聚粒子可以是精细内聚粒子。
内聚粒子可以是非颜料粒子，如精细非颜料内聚粒子。
内聚粒子，如精细非颜料内聚粒子可选自硅酸盐、硅氧化物、碳酸钙、硫酸钡、polytetrafluoreten。
内聚粒子，如精细非颜料内聚粒子可选自硅酸盐，如硅酸铝、硅酸镁或硅氧化物，优选SiO2，优选作为气相二氧化硅。
内聚粒子，如精细非颜料内聚粒子可选自碳酸钙(CaCO3，如Mikhart)、硫酸钡如BaSO4BB30EX、硅酸铝如Polygloss水合硅酸镁、煅烧硅酸铝(具有降低的结晶水含量的烧制生高岭土)、polytetrafluoreten如和气相二氧化硅如HDK
应该理解的是，内聚粒子是具有内聚吸引力或内聚力的粒子。内聚力是粒子粘在一起、相互吸引的作用或性质或诸如此类。这是由至少一个粒子的形状和结构造成的物质的固有性质，以形成可保持微观结构的电吸引力。换言之，内聚能够通过为粒子表面分子创造类似堆积体的环境来降低表面能。
精细粒子通常被理解为至少70％的粒子具有2.5μm或更小的在其最大维度中的长度，优选该粒子具有2.5μm或更小的在其最大维度中的长度。
精细内聚粒子，如精细非颜料内聚粒子因此是其中至少70％的粒子具有0.1μm至2.5μm的粒度，优选在其最大维度中的长度的粒子，以使粒子具有0.1μm至2.5μm的粒度，优选在其最大维度中的长度。
内聚粒子的内聚力可能超过所述至少一种填料的内聚力，以使内聚粒子涂布填料。如用标准Shear Cell Program，50mm shear 6kPa(FT4Powder Rheometer)测得的内聚粒子的内聚力可为至少0.25kPa，如0.25-3kPa。
根据一个方面，第一层中的内聚粒子，如精细非颜料内聚粒子以0.05重量％至9重量％的量存在于该混合物中。
优选地，该混合物中的内聚粒子，如精细非颜料内聚粒子的量可在0.3重量％至8.5重量％之间，优选在1重量％至7重量％之间，优选在2重量％至6重量％之间，优选在4重量％至5重量％之间。
在一个实施方案中，该混合物中的非颜料内聚粒子的量可为大约7.5重量％。
在一个实施方案中，该混合物中的非颜料内聚粒子的量可为大约2.5重量％。
在一个方面中，该混合物中的内聚粒子，如精细非颜料内聚粒子的量可在0.2重量％至4.5重量％之间，优选在0.2重量％至2.5重量％之间。
在一个方面中，该混合物中的内聚粒子，如精细非颜料内聚粒子的量可在0.3重量％至5重量％之间，优选在0.5重量％至5重量％之间，更优选在2重量％至4重量％之间。
在一个实施方案中，该混合物中的非颜料内聚粒子的量可为大约0.1重量％。
根据另一方面，精细非颜料内聚粒子选自硅酸盐，如硅酸铝或硅氧化物，优选SiO2，优选作为气相二氧化硅。
特别地，如果使用硅酸铝作为精细非颜料内聚粒子，该混合物中的硅酸铝的量可在0.5重量％至9重量％之间，如在0.5重量％至5重量％之间，优选在2重量％至4重量％之间。在一个方面中，该混合物中的硅酸铝的量可在0.3重量％至5重量％之间。
如果使用气相二氧化硅，如SiO2作为精细非颜料内聚粒子，该混合物中的硅氧化物的量可在0.05重量％至3重量％之间，优选在0.05重量％至0.7重量％之间，如在0.1重量％至0.7重量％之间，优选在0.3重量％至0.7重量％之间。
优选地，精细非颜料内聚粒子可选自碳酸钙(CaCO3，如Mikhart C)、BaSO4 BB30EX、Polygloss(硅酸铝)、水合硅酸镁、煅烧硅酸铝(具有降低的结晶水含量的烧制生高岭土)、(polytetrafluoreten)和HDK(气相二氧化硅)。
如果使用碳酸钙作为精细非颜料内聚粒子，该混合物中的碳酸钙的量可在0.3重量％至9重量％之间，优选在0.3重量％至5重量％之间，如在0.5重量％至5重量％之间，优选在2重量％至4重量％之间。在一个方面中，该混合物中的碳酸钙的量可在0.5重量％至9重量％之间。
如果使用硫酸钡作为精细非颜料内聚粒子，该混合物中的碳酸钙的量可在0.3重量％至9重量％之间，优选在0.3重量％至5重量％之间，如在0.5重量％至5重量％之间，优选在2重量％至4重量％之间。在一个方面中，该混合物中的硫酸钡的量可在0.5重量％至9重量％之间。
如果使用polytetrafluoreten作为精细非颜料内聚粒子，该混合物中的碳酸钙的量可在0.3重量％至9重量％之间，优选在0.3重量％至5重量％之间，如在0.5重量％至5重量％之间，优选在2重量％至4重量％之间。在一个方面中，该混合物中的polytetrafluoreten的量可在0.5重量％至9重量％之间。
根据另一方面，SiO2是气相二氧化硅。
在一个方面中，第一层可进一步包含颜料。
在另一方面中，第一层可基本不含颜料。
优选地，内聚粒子，如精细非颜料内聚粒子，具有小于1.9，如1.0-1.9的折射率(RI)。当折射率等于或低于1.9时，该精细非颜料内聚粒子比折射率大于1.9的粒子较少使第一层变色。由此，根据本发明的某些实施方案的精细非颜料内聚粒子不会显著影响第一层的某些性质，如颜色。
优选地，内聚粒子，如精细非颜料内聚粒子具有大约1.56的折射率，如该内聚粒子是硅酸铝。
优选地，内聚粒子，如精细非颜料内聚粒子具有大约1.46的折射率，如该内聚粒子是气相二氧化硅(如)。
内聚颜料粒子的折射率是描述光多快地传播经过该材料的数值并被定义为：
折射率(RI)＝光速/光在介质中的相速度。可用折射计，如来自Bellingham andStanley的OPTi Digital Range折射计测量折射率。
该干燥混合物优选包含30重量％至47重量％的填料，如木粉，优选33 -45重量％，更优选35重量％或44重量％。
该干燥混合物优选包含44重量％至70重量％的至少一种粘合剂(或粘合剂的混合物)，如49-54重量％或60-75重量％。
该干燥混合物优选包含0.05重量％至9重量％的内聚粒子，如精细非颜料内聚粒子。例如，当使用硅酸铝时，该混合物优选包含2-4重量％的量的硅酸铝。例如，当使用气相二氧化硅时，其优选以0.2-0.7重量％的量包含在干燥混合物中。
该混合物可以200-600g/m2，优选300-500g/m2，如大约400g/m2的量施加，由此形成第一层。施加的混合物中的粘合剂的量可为100-300g/m2，优选150-250g/m2，如大约200g/m2。
粘合剂、至少一种填料和精细非颜料内聚粒子的混合物可如图1A中所示分布在基底2的第一表面上以形成第一层1，或可与附加添加剂和/或耐磨粒子和/或颜料或染料混合以分布在基底2的第一表面上。
本发明人已经意外地发现，在上文公开的范围内添加到包含粘合剂和至少一种填料的干燥混合物中的精细非颜料内聚粒子增强第一层的干燥混合物的自由流动。
同时，将这样的粒子添加到均衡的组合物中对该混合物的其它性质没有实质性的负面影响。用于生产建筑构件的工艺参数，如压力、温度和时间保持基本不变。
本发明人已经发现，精细非颜料内聚粒子适合该用途并且不会实质性地以负面方式影响该混合物和第一表面层的任何其它参数。因此，包含粘合剂、至少一种填料和精细非颜料内聚粒子的混合物可形成如本文定义的建筑构件的第一层。
在该混合物中包括非颜料内聚粒子改进第一层的自由流动，由此实现该层的更好分布。其也改进在压制后第一层1对基底2的附着力。
第一层1也可具有由添加剂，如耐磨粒子提供的其它性质，如耐磨性质。耐磨粒子可以是氧化铝粒子，如刚玉。
第一层1可包含附加添加剂，如润湿剂、抗静电剂和/或导热添加剂，如铝、催化剂。
由精细非颜料内聚粒子的加入正面造成的该干燥混合物的可流动性改进在施加热和/或压力时建筑构件的固化，因为离开压机的板具有改进的形状。
由此改进产品的平衡。如果有平衡层5，其可能比业内常规使用的更薄。
可能在第一层1上或在基底2的第一表面上布置附加层或中间层，未显示在图1A-D中。中间层可能是，但不限于具有吸声性质的软木层或软木单板层。
可在压制前对第一层1施加水分。可通过施加热，例如通过IR或NIR将第一层1干燥和或稳定化。
如图1A中所示，将该混合物施加在基底2上以形成第一层1并通过对第一层1和/或基底2施加热和/或压力而压在一起。如果第一层1包括热固性粘合剂，通过施加热和/或压力将第一层1固化。优选可施加压力。施加的压力可在20至60巴之间。可通过连续压机或不连续压机对第一层施加压力。当压机不连续时，压力优选在40至60巴之间，或当压机连续时在20巴至60巴之间。温度优选在150℃至250℃之间。
优选在压制前，可任选在第一层1上施加表面层3。第一层1可在施加表面层1之前预压制，或可优选在压制前铺散到基底2上。
可在第一层1上施加表面层3，由此形成在第一层1上的第二层。表面层1可以是如图1C中所示的单板层。表面层可以是或包含木单板或软木单板。木单板的密度可为至少1000kg/m3，例如1000至5000kg/m3。木单板层可由压缩木单板形成。通过使木单板具有至少1000kg/m3的密度或压缩到1000kg/m3的密度，提高木单板的硬度。木单板是薄木层，例如具有0.2-1mm的厚度。表面层3可以是连续或不连续的。表面层3可由几个单板片段形成。表面层可以是重叠的或无重叠的。在单板片段之间可形成间隙。
当在第一层1上施加表面层3时，粘合剂，如上述类型的热固性粘合剂在压制过程中同时将表面层3与第一层1粘合。当对第一层1施加热和/或压力时，热固性粘合剂在发生交联前变成流体。施加的热和压力在将表面层3粘合到第一层1的同时导致第一层1的热固性粘合剂的固化。
在一个实施方案中，制成的建筑构件在压制后可为6-25mm厚，优选8-15mm厚，而基底可为5-22mm厚，优选7-14mm厚。第一层在压制后可为0.1-2mm厚。
通过上述方法的实施方案制成的示例性建筑构件10显示在图1B-D中。
在图1B中所示的实施方案中，建筑构件10是建筑面板(building panel)。该建筑构件包含如上所述的第一层1、上述类型的基底2和平衡层5。
在图1C中所示的实施方案中，建筑构件是建筑面板。该建筑构件包含如上所述的第一层1、上述类型的基底2和平衡层5。在图1C中所示的实施方案中，建筑构件10进一步包含表面层3，其包含木单板。
在图1D中所示的实施方案中，建筑构件10包含如上所述的第一层1，表面层3包含布置在第一层1上的第一木单板，且基底2包含布置在第一层1下方的第二木单板。
第一层可以粉末形式施加。
根据一个方面，建筑面板是地板或墙板。
根据一个方面，建筑构件10可包含布置在基底2上的第一层1，所述第一层包含粘合剂、至少一种填料和精细非颜料内聚粒子的混合物，其中通过对第一层1和/或基底2施加热和/或压力而组装所述建筑构件。
根据上述方面的建筑构件可包含先前已论述的该方法的所有优点，由此先前的论述也适用于建筑构件。
本文所述的实施方案预计有许多修改，它们仍在如所附权利要求书界定的本发明的范围内。例如，预计可在用于形成建筑面板的芯层上布置多于一个耐磨箔。
实施例
实施例1
用浓度递增的G90精细粒子硅酸铝制造包含木纤维和三聚氰胺-甲醛树脂的不同粉末制剂，以如表1中所示研究粉末自由流动与G90的浓度之间的关系。将粉末制剂置于玻璃罐中至其体积的大约一半并在通过向罐施加外力以让粉末流动时目视评价。考虑的典型粉末是流动的，没有形成聚集体并且没有表现出容易部分吸附于罐壁的厚尘形成。可接受的制剂具有比参考粉末(图2A)均匀的粒度分布(图2B)。
表1.使用不同浓度的G90的自由流动实验
制剂 ASP G90(重量％) MF(重量％) 木纤维(重量％)
A(Ref) 0 54 46
B 1 53.5 45.5
C 2 53 45
D 3 52.5 44.5
E 5 51.5 42.5
如目视评价，制剂B-E表现出明显高于参考粉末A(Ref)的自由流动。在制剂B和C之间有视觉上明显的改进，但在样品C、D和E之间没有显著差异。
实施例2
用浓度递增的200极精细粒气相二氧化硅制造包含木纤维和三聚氰胺-甲醛树脂的不同粉末制剂，以研究粉末自由流动与200的浓度之间的关系。混合物组成显示在表2中。如实施例1中所述评价粉末制剂。
表2.使用不同浓度的200的自由流动实验
制剂F和G表现出视觉上明显高于参考A(Ref)的自由流动，这进一步直观显示在图3A-3B中，其中与参考样品A比较显示样品F。
当制剂B-E和F-G进一步用于制造建筑构件的方法时，该制剂容易分布，没有形成聚集体。该制剂提供均匀层，由此改进第一层的性质和第一层与基底的粘合。
实施例3
四种标准化制剂(下表3中的A-D)，其中仅在不同的无机非颜料精细内聚粒子之间切换添加剂部分。这些制剂随后使用Freeman Technology FT4 Powder Rheometer运行渗透率程序，其中在不同压力下迫使空气经过粉末床。压降与渗透率直接成反比。获得压降vs.外加法向应力的曲线图，其中高压降归因于低渗透率，意味着粉末中的较高内聚。然后目视检查所有粉末并使用实施例1中提到的玻璃罐法比较可流动性。
表3.标准化制剂.
在图4A中显示渗透率结果，表明所有样品如预期那样表现得比参考物更内聚。所有样品在玻璃罐实验中也在视觉上表现得比参考物更自由流动。但是，在图4B中看出，当增加某种添加剂时，粉末内聚提高，自由流动的情况并非如此。参考物容易表现出成桥(机械联锁)，这在加入任何给出的添加剂时减轻，直至特定浓度，此时由于内聚力，自由流动又开始降低。这一实施例中给出的添加剂的最佳自由流动剂浓度为0.5-5重量％，高度取决于添加剂类型。
图4B显示C的渗透率结果，其中B、C、D代表表3中的不同制剂。图4C显示90的渗透率结果，其中A和C代表表3中的不同制剂。
当在本说明书中关于数值使用词语“大约”或“基本”时，相关数值意在包括在指定数值左右+/-10％的容差。

Claims (19)

1.一种制造建筑构件(10)的方法，其包含
在基底(2)的第一表面上施加第一层(1)，所述第一层(1)包含粘合剂、至少一种填料和非颜料内聚粒子的混合物，其中所述精细非颜料内聚粒子选自碳酸钙和硫酸钡，其中所述混合物中的精细非颜料内聚粒子的量为所述混合物的0.05重量％至9重量％，
其中至少70％的精细非颜料内聚粒子具有2.5μm或更小的在其最大维度中的长度，并且
其中所述非颜料内聚粒子被配置为当所述第一层(1)被施加在所述基底(2)的所述第一表面上时施加增加所述第一层(1)的混合物的可流动性，对第一层(1)和/或基底(2)施加热和/或压力，由此形成建筑构件(10)。
2.根据权利要求1的方法，其中所述内聚粒子的内聚力超过所述至少一种填料的内聚力。
3.根据权利要求1或2的方法，其中如用标准Shear Cell Program，50mm shear 6kPa(FT4 Powder Rheometer)测得的所述内聚粒子的内聚力为至少0.25kPa。
4.根据前述权利要求任一项的方法，其中所述混合物以干燥形式施加。
5.根据前述权利要求任一项的方法，其中所述混合物通过铺散施加。
6.根据前述权利要求任一项的方法，其中所述精细非颜料内聚粒子具有小于1.9的折射率(RI)。
7.根据前述权利要求任一项的方法，其中所述至少一种填料包含木粉。
8.根据前述权利要求任一项的方法，其中所述粘合剂是热固性粘合剂。
9.根据前述权利要求任一项的方法，其中第一层(1)进一步包含耐磨粒子。
10.根据前述权利要求任一项的方法，其中第一层(1)进一步包含颜料粒子。
11.根据前述权利要求任一项的方法，其中基底(2)是木质板、刨花板、热塑板、胶合板、薄片芯、单板层。
12.一种建筑构件(10)，其包含
布置在基底(2)上的第一层(1)，所述第一层(1)由包含粘合剂、至少一种填料和非颜料内聚粒子的混合物形成，其中所述精细非颜料内聚粒子选自碳酸钙和硫酸钡，
其中所述混合物中的精细非颜料内聚粒子的量为所述混合物的0.05重量％至9重量％，其中至少70％的精细非颜料内聚粒子具有2.5μm或更小的在其最大维度中的长度，并且
其中通过施加热和/或压力形成所述建筑构件(10)。
13.根据权利要求12的建筑构件，其中所述内聚粒子的内聚力超过所述至少填料的内聚力。
14.根据权利要求12或13的建筑构件，其中如用标准Shear Cell Program，50mm shear6kPa(FT4 Powder Rheometer)测得的所述内聚粒子的内聚力为至少0.25kPa。
15.根据权利要求12-14任一项的建筑构件，其中所述至少一种填料包含木粉。
16.根据权利要求12-15任一项的建筑构件，其中所述粘合剂是热固性粘合剂。
17.根据权利要求12-16任一项的建筑构件，其中第一层(1)进一步包含耐磨粒子。
18.根据权利要求12-17任一项的建筑构件，其中第一层(1)进一步包含颜料粒子。
19.根据权利要求12-18任一项的建筑构件，其中基底(2)是木质板、刨花板、热塑板、胶合板、薄片芯、单板层。
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