U.S. patent application number 16/307321 was filed with the patent office on 2019-10-31 for a composite board and the method for producing it.
The applicant listed for this patent is Angle World LLC. Invention is credited to Cheng Hang, Wenyue Hu, Jae-song Pyon, Biao Wang.
Application Number | 20190330860 16/307321 |
Document ID | / |
Family ID | 68163040 |
Filed Date | 2019-10-31 |
United States Patent
Application |
20190330860 |
Kind Code |
A1 |
Wang; Biao ; et al. |
October 31, 2019 |
A COMPOSITE BOARD AND THE METHOD FOR PRODUCING IT
Abstract
The present invention provides a composite board and the method
for producing it, wherein the composite board includes a base
material layer constituting the core part of the composite board; a
wear layer covering and fixed on the base material layer; a
substrate layer which is fixed on the other side of the base
material layer opposite to the wear layer; and the first binding
layer which is bound between the base material layer and the wear
layer, wherein the base material layer further includes fixings on
its both sides, and when at least two composite boards are
connected together, the fixings can be coupled with each other to
relatively fix the composite boards. The aforementioned method and
techniques can enable composite boards to be as rigid and
wear-resistant as a tile and moreover, can reduce the time and
labor costs required for the installation of the tiles by applying
the base material layer in the installation of composite
boards.
Inventors: |
Wang; Biao; (Changzhou,
CN) ; Hu; Wenyue; (Changzhou, CN) ; Pyon;
Jae-song; (Philadelphia, PA) ; Hang; Cheng;
(Changzhou, CN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Angle World LLC |
Philadelphia |
PA |
US |
|
|
Family ID: |
68163040 |
Appl. No.: |
16/307321 |
Filed: |
April 13, 2018 |
PCT Filed: |
April 13, 2018 |
PCT NO: |
PCT/CN2018/083120 |
371 Date: |
December 5, 2018 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E04F 13/0894 20130101;
E04F 15/085 20130101; E04F 13/14 20130101; E04F 13/144 20130101;
E04F 13/0866 20130101; E04F 13/142 20130101; B32B 2307/554
20130101; E04F 2201/026 20130101; E04F 13/075 20130101; B32B 7/02
20130101; E04F 15/02038 20130101; B32B 2309/105 20130101; E04F
15/107 20130101 |
International
Class: |
E04F 15/10 20060101
E04F015/10; E04F 13/075 20060101 E04F013/075 |
Claims
1. A composite board including a base material layer constituting
the core part of the composite board; a wear layer covering and
fixed on the base material layer; a substrate layer which is fixed
on the other side of the base material layer opposite to the wear
layer; the first binding layer which is bound between the base
material layer and the wear layer, wherein the base material layer
further includes fixings on its both sides, and when at least two
composite boards are connected together, the fixings will be
coupled with each other to relatively fix the composite boards.
2. The composite board of claim 1, wherein the base material layer
includes a composite material made of stone powder and plastic; and
the wear layer includes rigid materials.
3. The composite board of claim 2, wherein the composite material
is WPC wood-plastic flooring or SPC stone-plastic flooring; and the
rigid materials are tiles or stone materials.
4. The composite board of claim 1, wherein the base material layer
and the wear layer are molded by a high temperature or cold
pressing after they are glued together.
5. The composite board of claim 1, wherein the composite board
further includes the second binding layer between the base material
layer and the substrate layer.
6. The composite board of claim 1, wherein the fixing is a
lock-catch type; and the lock-catch fixing includes a mounting
groove and a mounting tongue for realizing the coupling and
fixation of the said multiple base material layers.
7. The composite board of claim 6, wherein the mounting tongue
includes a stopper groove; and the mounting groove on its surface
has a stopper tongue; the stopper tongue couples with the stopper
groove, so as to limit the axial and radial movements between the
said multiple base material layers.
8. The composite board of claim 1, wherein the base material layer
includes a mounting surface oriented toward the wear layer; and the
wear layer has a pair of edges fit with the ones of the mounting
surface, and another pair of edges set within the projection area
of the mounting surface.
9. The composite board of claim 1, wherein the wear layer on its
surface has decorative joints which are parallel with the direction
along the width of the wear layer.
10. A method for producing the composite boards, which includes the
following steps: Step S100: Take a base material layer as the core
part of the composite board; Step S200: Set fixings on both sides
of the base material layer, which are used to relatively fix the
composite boards; Step S300: Set and fix a wear layer on the base
material layer.
Description
TECHNICAL FIELD
[0001] The present invention relates to the field of building
materials, and in particular to a composite board and the method
for producing it.
BACKGROUND ART
[0002] In the field of building materials, the boards used on
floors or walls are usually required to be water and moisture
resistant, low-cost and not easily deformed. For this reason,
laminated floor boards made of fibers or particles, and rigid
products such as tiles and stone materials are popular in the
market. Depending on different needs, users may use wood, plastic
or hard materials on their floors or wall surfaces.
[0003] Rigid materials such as tiles and stone materials have a low
deformation-bearing capacity, though they are good for decoration,
easy to be cleaned and free from corrosion by dirt. Tiles and stone
materials may be cracked or broken under stress, so binding agents
and cement are often used to manually install tiles and stone
materials on walls or floors. Besides, no structure for
inter-fixation is additionally provided on a tile or a stone
material during or after the cutting process
[0004] Even if we use common materials, which are more tenacious
but accordingly less rigid, to replace tiles and stone materials,
we still face other problems such as a lower rigidity and a higher
vulnerability to scratches.
[0005] Thus we need a new type of composite board which is as rigid
and wear resistant as a title and moreover, which have a board core
that can serve as a composite board and reduce the time and labor
costs required for the installation of the tiles while maintaining
the water and heat resistance of the title and the base
material.
SUMMARY OF THE INVENTION
[0006] To overcome the aforementioned technical deficiencies, the
present invention provides a composite board and the method for
producing it, by which a green installation process can be realized
by reducing the use of binding agent and thus the harmful
substances produced by the agent during the tile installation
process, and by enhancing the use efficiency of the individual
parts of the materials. This will bring a promising future to
product lines of the home decoration industry.
[0007] The present invention discloses a composite board, which
includes a base material layer constituting the core part of the
composite board; [0008] a wear layer covering and fixed on the base
material layer; [0009] a substrate layer which is fixed on the
other side of the base material layer opposite to the wear layer;
[0010] the first binding layer which is bound between the base
material layer and the wear layer, wherein [0011] includes fixings
on its both sides, and when at least two composite boards are
connected together, the fixings will be coupled with each other to
relatively fix the composite boards.
[0012] Optimally, the base material layer includes a composite
material made of stone powder and plastic;
[0013] The wear layer includes rigid materials.
[0014] Optimally, the composite material is WPC wood-plastic
flooring or SPC stone-plastic flooring;
[0015] The rigid materials are tiles or stone materials.
[0016] Optimally, the base material layer and the wear layer are
molded by a high temperature or cold pressing after they are glued
together.
[0017] Optimally, the composite board further includes the second
binding layer between the base material layer and the substrate
layer.
[0018] Optimally, the fixing is a lock-catch type;
[0019] The lock-catch fixing includes a mounting groove and a
mounting tongue for realizing the coupling and fixation of the said
multiple base material layers.
[0020] Optimally, the mounting tongue includes a stopper groove,
and the mounting groove on its surface has a stopper tongue;
[0021] The stopper tongue couples with the stopper groove, so as to
limit the axial and radial movements between the said multiple base
material layers.
[0022] Optimally, the base material layer includes a mounting
surface oriented toward the wear layer;
[0023] The wear layer has a pair of edges fit with the ones of the
mounting surface, and another pair of edges set within the
projection area of the mounting surface.
[0024] Optimally, the wear layer on its surface has decorative
joints;
[0025] The decorative joints are parallel with the direction along
the width of the wear layer.
[0026] The present invention also discloses a method for producing
the composite boards, which includes the following steps:
[0027] Step S100: take a base material layer as the core part of
the composite board;
[0028] Step S200: set fixings on both sides of the base material
layer, which are used to relatively fix the composite boards.
[0029] Step S300: set and fix a wear layer on the base material
layer.
[0030] Compared with existing technologies, the aforementioned
method and techniques have the following advantages:
[0031] 1. Solve the installation problems where rigid materials
such as tiles and stone materials are used as building materials,
which greatly saves labor and time costs;
[0032] 2. Reduce the use of binding agent and thus the harmful
substances produced by the agent during the tile installation
process, being consistent with the trend of green decoration;
[0033] 3. Provide a nearly perfect composite board that takes
advantage of both the rigidity of the wear layer and the tenacity
of the base material layer and thus can be used in all
situations;
[0034] 4. Under a situation with abnormal changes in temperature,
the resistance of the base material layer to water, moisture and
deformation can prevent excessive deformation and impacts on the
structure of the composite board involved in the present
invention.
DESCRIPTION OF ATTACHED FIGURES
[0035] FIG. 1 is the structure of an exemplary composite board
according to the invention;
[0036] FIG. 2 is the structure comprising the first binding layer
of an exemplary composite board according to the invention;
[0037] FIG. 3 is the structure comprising the second binding layer
of an exemplary composite board according to the invention;
[0038] FIG. 4 is the structure comprising both the first and second
binding layers of an exemplary composite board according to the
invention;
[0039] FIG. 5 is the structure of the lock-catch fixing on the base
material layer of an exemplary composite board according to the
invention;
[0040] FIG. 6 is the structure of the lock-catch fixing on the base
material layer of another exemplary composite board according to
the invention;
[0041] FIG. 7 is the structure of the lock-catch fixing on the base
material layer of another exemplary composite board according to
the invention;
[0042] FIG. 8 is the structure of the lock-catch fixing on the base
material layer of another exemplary composite board according to
the invention;
[0043] FIG. 9 is the structure of the lock-catch fixing on the base
material layer of another exemplary composite board according to
the invention;
[0044] FIG. 10 is the structure of the lock-catch fixing on the
base material layer of another exemplary composite board according
to the invention;
[0045] FIG. 11 is the structure of an exemplary composite board
with decorative joints according to the invention;
[0046] FIG. 12 is the structure of another exemplary composite
board with decorative joints according to the invention;
REFERENCE
[0047] 100--Composite Board; [0048] 110--Base Material Layer,
111--Lock--catch Fixing, 112--Mounting Groove, 113--Mounting
Tongue, 114--Stopper Groove, 115--Stopper Tongue; [0049] 120--Wear
Layer, 121--Decorative Joints; [0050] 130--Substrate Layer; [0051]
140--First Binding Layer; [0052] 150--Second Binding Layer.
SPECIFIC EMBODIMENTS
[0053] In the following sections, the advantages of the present
invention will be expounded through figures and specific
embodiments.
[0054] Typical embodiments will be described in detail in this
article, with examples shown in these attached figures. Unless
otherwise specified, the same numbers shown in different figures
involved in the following description shall mean the same or
similar elements. The embodiments described in this article do not
represent all of embodiments consistent with what has been
disclosed in this article. On the contrary, they are only some
examples in conformity with the information disclosed herein as
well as the devices and methods that have been explained in detail
in the attached Patent Claims.
[0055] The terms used in this disclosure are only to describe
specific embodiments rather than limit this disclosure. The
singular "a type of", "the said" and "it" used in this disclosure
and the attached Patent Claims shall also include their plural
forms, unless their other meanings are otherwise specified in
context. It shall also be understood that the terms "and/or" used
in this article refer to and include any or all possible
combinations of one or more associated and listed items.
[0056] It shall be understood that although the terms "first,
second, third, etc." may be used in this disclosure to describe
information, the information described shall not be limited by
these terms. These terms are used only to categorize the
information of the same type. For example, without exceeding the
range of this disclosure, the "first information" might as well be
called as the "second information". Similarly, the "second
information" might be called as the "first information. The term
"if" may be interpreted as "when" or "where" or "in response to a
certain case", which depends on the context.
[0057] It shall be understood in the description of the present
invention that the directions or locations indicated by terms such
as "longitudinal", "transversal", "up", "down", "front", "back",
"left", "right", "vertical", "horizontal", "top", "bottom",
"inside" and "outside", are only based on the directions or
locations shown in the attached figures. These terms are only used
to facilitate and simplify the description of the present invention
rather than refer to or imply that the stated device or unit must
be in a specific direction or at a specific location to be built or
operate, and thus shall not be interpreted as a limit on the
present invention.
[0058] It is needed to be explained that in the description of the
present invention, unless otherwise specified and limited, the
terms "installation", "link" and "connection" shall be interpreted
expansively. For example, "connection" may refer to a mechanical
connection, an electric connection, an internal connection between
two units, a direct connection or an indirect connection via a
medium. An ordinary technician of this field may interpret the said
terms according to the actual situation.
[0059] In the following description, the postpositional terms that
are used to indicate an element, such as "module", "component" or
"unit", are only to facilitate the description of the present
invention and have no specific meaning. Therefore, "module" and
"component" may be used together.
[0060] See FIGS. 1 to 4. These figures show the structure of the
composite board 100 of an optimal embodiment of the present
invention. In the embodiment the composite board 100 includes four
basic layers: the base material layer 110, the wear layer 120, the
substrate layer 130 and the first binding layer 140. The base
material layer 110, as the core part of the composite board 100, is
set in the middle of the composite board 100 or serves as a bottom
layer to fit together with the composite board 100 and the ground
surface or wall surface. The wear layer 120 is fixed on the base
material layer 110 by a binding agent or in other ways without need
of binding agent. The first binding layer 140 is bound between the
base material layer 110 and the wear layer 120. The first binding
layer 140 may be a PVC layer used to enhance the tenacity of the
base material layer 110. The substrate layer is set against the
base material layer 110 on one side (the other side of the base
material layer 110 is against the wear layer 120), namely, the wear
layer 120 and substrate 130 are set on both sides of the base
material layer 110, respectively. Similarly, the substrate layer
130 is fixed together with the base material layer 110. The
optional substrate layer 130 may be made of IXPE plastic layer, EVA
or Cork layer in order to reduce noise and increase the flexibility
of the composite board 100.
[0061] More specifically, the wear layer 120 is oriented toward the
ground surface or wall surface on which the composite board is to
be installed, and will bear the friction with furniture and users.
The surface of the wear layer 120 may optionally coated with
antiskid, wear resistant and/or matte films, which can enhance its
wear resistance and/or appearance.
[0062] In an optimal embodiment, the base material layer 110
includes a composite material made of stone powder and plastic; or
is an ordinary wooden floor board or a pressed material containing
particles of bamboo and/or wood or soft chips of wood or a mixture;
or is made of high-density polyethylene materials without chip-like
materials, or of original or recycled PVC or the mixture of the
both. Regardless of which ingredient described above is used, the
composite material is shaped and made into a composite board 100.
Similarly, the wear layer 120 includes rigid materials or consists
of mainly rigid materials and other ingredients.
[0063] More specifically, the composite material included in the
material base layer is WPC wood-plastic flooring or SPC
stone-plastic flooring. SPC stone-plastic flooring mainly consists
of polyvinyl chloride, calcium carbonate, stabilizing agent, ADC
foaming agent, NC foaming agent and one or more of other chemical
additives such as lubricant, antibacterial agent, stabilizing
agent, color matching agent, anti-UV agent and binding agent. The
method for producing SPC stone-plastic flooring: use an extruding
machine and T-shape moulds to squeeze out the PVC base material;
use a three- or four-roll flattener to finish the mixing of PVC
wear layer, PVC color film and PVC base material, as well as
embossing and shaping by heat in just one process. This process is
simple that the combination is realized only by heat without using
any glue. More specifically, the production process includes the
following steps:
[0064] 1. Mixing Materials
[0065] Place the materials in a prescribed ratio into the
high-speed mixing machine to mix well the materials by heat (the
hot-rolling temperature may be 125.degree. C.) and eliminate the
moisture contained in the materials; after the hot-rolling process,
the materials proceed to the cold-rolling process (the cold-rolling
temperature may be 55.degree. C.), which is to bring down the
temperature of the materials and prevent agglomeration and
discoloration; cool down the well-mixed materials in the end.
[0066] 2. Extruding
[0067] Materials are put into the double-screw extruder to be
heated and squeezed out to the sheet-making mould head to be
processed into sheets. Then the sheets are treated by the four-roll
flattener to get a specific thickness. Multiple steps then are
taken to finish color coating and wear layer 120 binding (this may
be omitted in this invention) on the base material layer. Then the
processed ones are cut and shaped.
[0068] 3. UV Tempering
[0069] The shaped products proceed to undergo surface UV treatment
and tempering (the hot water temperature to be used ranges from 80
to 120.degree. C. and the cold water temperature is about
10.degree. C.).
[0070] 4. Slitting, Slotting and Packaging
[0071] Finally the materials are slit, slotted, trimmed, chamfered
and inspected. Then the products that have passed the inspection
are packaged and transferred out.
[0072] The materials used to produce SPC stone-plastic flooring are
environmentally friendly and free from formaldehyde and other
harmful substances such as heavy metals, phthalic acid ester and
methyl alcohol. With a thickness ranging from only 4 to 5.5 mm, SPC
stone-plastic flooring has a structure resistant to water, fire and
wet, and it is free from toxin and odor. Moreover, SPC
stone-plastic flooring is better than laminate flooring in terms of
scratch resistance, resource use efficiency and anti-skid
performance. In addition to the aforementioned properties, SPC
stone-plastic flooring also has a contractibility rate
.ltoreq.1.Salinity. (after tempering) or .ltoreq.2.5.Salinity.
(before tempering), a density ranging from 1.9 to 2 tons per cubic
meter, and thus stable and reliable physical and chemical
parameters meeting international and national standards.
[0073] WPC (abbreviation of Wood Plastic Composition) wood-plastic
flooring is a product made by mixing well wooden raw materials
(taking wood cellulose and plant cellulose as the base materials),
thermoplastic high polymer materials (plastic) and processing aids
and shaped by a heat-based molding and extruding machine. Thus WPC
flooring integrates the properties and features of both wooden and
plastic materials. In addition to the aforementioned ingredients,
WPC flooring also involves one or more of foam regulator (methyl
methacrylate-butyl acrylate-styrene polymer), calcium-zinc
stabilizer (zinc stearate and calcium stearate), internal lubricant
60, PE wax (Fischer-Tropsch wax), ADC foaming agent, NC foaming
agent, and high-temperature lubricant (oxidized polyethlene wax).
With the same properties as woods, WPC flooring can be use
conveniently like an ordinary wooden material, such as being cut by
saw, drilled or nailed. And WPC flooring has both a wood-like
texture and a plastic-like resistance to water and corrosion,
making it an excellent out-door building material with high
durability.
[0074] Besides, WPC flooring also has the following properties:
[0075] 1. Physical properties: high strength and rigidity,
anti-skid performance, wear resistance, insect damage immunity, low
water absorbability, electrical insulation, as well as resistance
to aging, corrosion, static electricity, ultraviolet, heat and fire
(can withstand a temperature ranging from -40.degree. C. to
75.degree. C.).
[0076] 2. Environmental-friendly performance: it is made from
ecologically and environmentally friendly woods which are
reproducible, and is free from toxins, dangerous chemical
components, anti-corrosion agents, formaldehyde and benzene,
causing no damage to the atmosphere or the environment. And it is
100% recyclable, reusable by processing technologies, and
biodegradable.
[0077] 3. Appearance and texture: it has a wood-like appearance and
texture, and a dimensional stability better than woods; and will
not produce cracks, twists or deformation. The product can be made
in multiple colors and can maintain its surface color for a long
period without needing of second-time painting.
[0078] 4. Capability of being processed: it has the same properties
as woods with which it can be secondarily processed--for example,
it can be cut with a saw, planed or glued, or fixed by nails or
screws. Meeting the specifications and standards for shaped
materials, it is easy to use during construction and
installation--it can be processed into a variety of facilities and
products through common methods.
[0079] Except for the aforementioned WPC wood-plastic flooring and
SPC stone-plastic flooring, it shall be understood that the base
material layer 110 may also be made of a wooden base board
containing or not containing wood powder, a PVC wood-plastic
flooring and/or PVC stone-plastic flooring. As the base material
layer 110 needs resistance to water, wet, high and low
temperatures, WPC wood-plastic flooring and SPC stone-plastic
flooring are the better choices for it.
[0080] Correspondingly, the rigid materials may be tiles or stone
materials. The components of a tile mainly are three mineral
materials: clay, quartz and feldspar and some chemical materials.
Clay (kaolin) is a plastic substance mainly made of
Al.sub.2O.sub.3, which produce plasticity and viscosity during the
production process and maintains the resistance to bending loads
after the drying process and other functional performances after
the baking process. Quartz (silica sand), mainly made of SiO.sub.2,
is a solidifying substance used to reduce adhesiveness. During the
baking process, some quartz is dissolved in feldspar glass to
enhance liquid viscosity and prevent high-temperature deformation.
After the porcelain is cooled down, quartz plays a support role
(like a skeleton to support a man). Feldspar (stone powder), mainly
made of K2O, Na2O, CaO and MgO, is a flux material which can fuse
part of quartz and the substances decomposed from Kaolin. The fused
high-viscosity glass can glue materials at a high temperature.
Glaze is a colored or colorless vitreous substance fused on to the
surface of pottery. Glaze slip is made of ground mineral materials
(feldspar, quartz, talc and kaolin) and chemical materials in a
prescribed ratio (some of the raw materials may be made into frits
in advance). Then the glaze slip is applied on a pottery and baked
at a particular temperature to become the glaze. Glaze can enhance
the mechanical strength, heat stability, dielectric strength and
appearance of the product. And a glazed product is easy to clean
and free from corrosion by dirt.
[0081] Stone materials can be categorized into two types: natural
stones and artificial stones. Marble is a kind of natural stone
material usually used for flooring, while quartz stone is an
artificial one for the same purpose. Marble, namely metamorphosed
limestone is mainly made of CaCO.sub.3; quartz is mainly made of
SiO.sub.2. Marble is usually used as a building material, while
quartz is commonly processed into quartz sand, quartz-based
fireproof materials and artificial boards. As a natural stone
material, marble has an uneven texture along with cracks or holes,
and may involve radiation or harmful substances. All of the stone
materials mentioned above have a tight structure, high compressive
strength, rigidity, and resistance to wear, wet and
temperature-induced deformation, a natural, thick and stately
texture, an extremely low swelling coefficient, a long service life
and good stability on a flat surface. And they are easy to maintain
and free from magnetization and dull appearance.
[0082] As the existing rigid materials have the aforementioned
properties, in installation we need to apply a binding agent or
cement on the bottom surface of the tile or stone material to
secure it one by one on the mounting surface according to the
design of the flooring or wall, requiring so much time and labor.
According to the aforementioned embodiments, the base material
layer 110 has a high tenacity and resistance to temperature-induced
deformation; the wear layer 120 has a high rigidity, but is easy to
crack under stress. After being combined with the wear layer 120,
the base material layer 110 serve can facilitate the installation,
while the wear layer 120 can further enhance the resistance of the
base material layer 110 to pressure and deformation. Furthermore,
fixings are built in or additionally installed on both sides of the
base material layer 110. If a user wants to combine two or more
composite boards 100 together, he/she just needs to match and
connect together the fixings of which one is on a side (for
example, the left side) of a base material layer 110 of a composite
board 100 and the other one is on a side (for example, the right
side) of the neighboring base material layer of another composite
board 100, and then the two composite boards 100 will be fixed
together. And it shall be understood that no binding agent is
required for the wear layer 120 during the installation process.
All the materials as well as mounting surfaces needed for the
installation are provided by the base material layer, which saves
great labor and time costs.
[0083] When a composite board 100 is being shaped, the first
binding layer 140 between the base material layer 110 and wear
layer 120 can be shaped together by high-temperature pressing or by
low-temperature pressing combined with binding agent applied on
both sides of the first binding layer 140. This process can be
finished in the factory producing the composite board 100 without
need of on-site operation by a user. The composite board 100 may be
installed on a self-leveling or a leveled ground or wall surface,
for example, a cement floor, a terrazzo floor or a floor made of
tile, marble and/or wood. And it is required to remove greasy dirt,
dust and any residue on the floor or wall surface before
installation. The installation of composite boards 100 may begin
with consideration of the shape of the base material layer 110 and
from the upper left corner of the room in which mounting surfaces
are ready. Place the first composite board 100 and make sure that
the fixings are outward and exposed. Reserve some space between the
ground and wall surfaces in case the composite floor swells
naturally. The larger area of installation, the wider reserved
space is required. When installing the second composite board 100
in the first row, one should insert the fixing of the second
composite board 100 into the fixing of the first composite board
100. Then install the other composite boards 100 in the first row
and finish the installation of all composite boards 100 in the same
way.
[0084] See FIGS. 3 and 4. In these different embodiments of which
one includes the first binding layer 140 but the other one does
not, the composite board 100 may further include the second binding
layer 150, which is bound between the base material layer 110 and
the substrate layer 130. If no substrate layer 130 is provided in
an embodiment, the composite board may be installed on the surface
via the second binding layer 150. The second binding layer 150 may
be a PVC layer, which can be installed on the surface by binding
agent. And because of the binding strength between the PVC layer
and the ground surface, the composite board 100 as a whole will be
more firmly fixed.
[0085] In another optimal embodiment, lock-catch fixings 111 are
set on the base material layer 110. The lock-catch fixings 111 are
to be use in pairs and built in the WPC wood-plastic flooring or
SPC stone-plastic flooring. Each pair of lock-catch fixings are set
on both sides of the base material layer 110. That is to say, the
fixings set on both sides of each base material layer 110 are
unsymmetrical. Take the mounting groove 112 and mounting tongue 113
as an example: when the mounting tongue 113 of the base material
layer 110 is inserted into the mounting groove 112 of the
neighboring board, the two fixings will be matched and coupled to
fix together the two neighboring base material layers 110.
[0086] See FIGS. 2 to 10. These figures show the structures of
lock-catch fixings of different embodiments. According to the
embodiments shown in these figures, mounting tongue 113 of
lock-catch fixing 111 further includes the stopper groove 114. The
stopper tongue 115 is set on surface of the mounting groove 112. In
order to couple the mounting groove 112 with the mounting tongue
113, it is required to insert the mounting tongue 113 into the
mounting groove 112 transversally rather than along the direction
of the opening. This is because the opening of the mounting groove
112 is designed to be smaller than the tip of the mounting tongue
113 (the tongue cannot enter the groove if it goes along the
direction of the opening). Furthermore, because of the design of
the stopper groove 114 and stopper tongue 115, in a transversal
insertion, the stopper tongue 115 will be coupled with and stuck in
the stopper groove 114, which further limits the axial and
longitudinal movements between the base material layers 110. The
cross sections of the mounting groove 112, mounting tongue 113,
stopper groove 114 and stopper tongue 115 may be in various
irregular shapes, such as a trapezoid or a triangle. It shall be
understood that the mounting groove 112 and stopper groove 114 are
not fully coupled with the mounting tongue 113 and stopper tongue
115, respectively, as there is some space reserved between them to
accommodate heat-induced deformation and to facilitate assembly and
disassembly.
[0087] See FIG. 11. Both the base material layer 110 and the wear
layer 120 are in the shape of a rectangle. The surface of the base
material layer 110 toward the wear layer 120 is a mounting surface.
When the wear layer 120 is mounted on the mounting surface of the
base material layer 110 to constitute the integral structure of the
composite board 100, the size of the wear layer 120 is equal to or
smaller than that of the mounting surface of the base material
layer 110, which allows the pair of edges of the wear layer 120 to
fit with that of the mounting surface, so that when the composite
board 100 is installed on a ground or wall surface, one cannot see
the edges of the base material layer 110 when his line of sight is
vertical to the ground or wall surface. The another pair of edges
of the wear layer 120 may be designed to be aligned with the base
material layer 110 or more close to the inside so that the edges
are within the projection area of the mounting surface--in other
words, upon the installation of the neighboring composite boards
110, their base material layers 110 will be against each other
tightly while their wear layers 120 will have some space between
them, which is reserved for fillers or decorative joints 121 of
tiles.
[0088] The pair of edges mentioned above refers to a pairs of long
or short edges on a base material layer 110 or a wear layer 120. If
the base material 110 and/or wear layer 120 is in an irregular
shape, then the pair of edges may refer to two neighboring or
non-neighboring straight lines or curves.
[0089] See FIG. 11 again. The wear layer 120 may consist of
multiple sections assembled together or be an integral structure.
When multiple sections of a wear layer 120 are glued and assembled
on a base material layer 110, some space are reserved between the
sections for decorative joints 121; in the case of an integral
structure, concave decorative joints 121 are set on the surface of
the wear layer 120 and parallel with the width direction of the
wear layer 120. With the product mentioned above, a user does not
need to do additional work to make decorative joints 121. In other
words, the multiple steps required for the tile installation are
finished during the production process of the composite boards 100,
which saves great labor and time costs.
[0090] See FIG. 12. Unlike FIG. 11, the base material layer 110 and
wear layer 120 has been divided into multiple sections in advance
to form decorative joints. As shown in the figure, a single base
material layer 110 is covered by a wear layer 120. In this case,
what would the products look like after they are installed has been
determined during the production process, by which the installation
process is further simplified.
[0091] The present invention also provides the method for producing
the composite boards, which includes the following steps:
[0092] Step S100: Take a base material layer as the core part of
the composite board;
[0093] Step S200: Set fixings on both sides of the base material
layer, which are used to relatively fix the composite boards.
[0094] Step S300: Set and fix a wear layer on the base material
layer. Upon the installation of the base material layer, the
position of the wear layer will be fixed too because the wear layer
is fixed together with the material base layer. Therefore, no
mounting structure is needed for the wear layer--the job is done by
the base material layer.
[0095] In the aforementioned production method it shall be
understood that according to the most basic requirements of the
construction industry, the composite boards should have the same
thickness; namely, the thicknesses of the base material layers and
the wear layers of the composite boards installed on the same
mounting surface should be the same. Furthermore, as the base
material layer is used for mounting and fixation, it can replace
some of the existing tiles without increasing the thickness of the
existing tile floor, namely, without reducing the indoor space or
storey height.
[0096] It should be noted that although the embodiments of the
present invention are optimal, they shall not limit the present
invention in any way. Any technician who is familiar with this
field might modify or change the technical information disclosed
above into the same effective embodiments which however, are not
detached from the technical solution of the present invention. Any
modification or non-substantive change or modification in the
aforementioned embodiments according to the substantial technical
solution of the present invention shall be covered by the technical
solution of the present invention.
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