US20140057066A1

US20140057066A1 - Building boards and method for manufacturing the same

Info

Publication number: US20140057066A1
Application number: US14/111,333
Authority: US
Inventors: Hongliang Cai
Original assignee: NEWSPIRIT CHINA LTD
Current assignee: NEW SPIRIT CHINA Ltd; NEWSPIRIT CHINA LTD
Priority date: 2011-04-12
Filing date: 2012-04-12
Publication date: 2014-02-27
Also published as: EP2697444A1; EP2697444A4; WO2012139510A1; CN102337770A

Abstract

Building boards and method for manufacturing the same are provided. The building board comprises a cement layer (102) and a magnesium oxide layer (104). The method for manufacturing the building board comprises the steps of providing a cement board and a magnesium oxide board, dehydrating and binding the cement board and the magnesium oxide board. The performance of moisture proofing, fungus proofing, erode proofing, fireproof and others can be improved by utilizing the building boards.

Description

TECHNICAL FIELD

This invention relates generally to the field of building decoration materials technology, and more particularly to a building board and the method for manufacturing the same.

BACKGROUND OF THE INVENTION

A conventional building board, such as laminate flooring, comprises 2 or 3 wooden layers to make the flooring stable. For 3-layer wooden building boards, an outer layer is generally made of wooden material having certain wood grain patterns, and the surface thereof can be further coated with paints to improve the decorative effect; and an inner layer is normally made of wooden layers with plywood structure or other cheaper woods. The wooden layers of the inner layer provide effects of buffering and soundproofing, thus it further improves user experience.
However, in practical applications, the building board made of wooden layers is easy to corrode and deform after water ingress or wetting, or deform under humid conditions, and therefore the user experience is affected. Moreover, the manufacturing of wooden building board needs a huge amount of wood with high-energy consumption, which could severely destroy the natural environment.

SUMMARY OF THE INVENTION

There is a need to provide a building board that features erode proofing, free of deformation, and more environment-friendly.
Accordingly, in an embodiment of the present invention, a building board is provided, and the building board comprises a cement layer and a magnesium oxide layer.
Alternatively, the cement layer and the magnesium oxide layer are bound with glue.
Alternatively, the cement layer comprises cement and glass fiber.
Alternatively, the cement layer has a thickness from 2 to 20 millimeters.
Alternatively, the magnesium oxide layer has a thickness from 8 to 15 millimeters.
Alternatively, the cement layer has a density from 1.1 to 1.8 g/cm³.
In another embodiment of the present invention, a laminate flooring is provided. The laminate flooring comprises a cement layer and a magnesium oxide layer.
Alternatively, the laminate flooring further comprises a buffer layer, wherein the buffer layer is connected with the magnesium oxide layer.
Alternatively, the buffer layer comprises rubber or plastics.
Alternatively, the laminate flooring is shaped as square, rectangle, parallelogram, hexagon or octagon.
Alternatively, the laminate flooring is covered with a protective coating.
Alternatively, the protective coating is oil or varnish.
Alternatively, each side of the laminate flooring has tongue or groove to joint to each other, or has click system to joint to each other.
In a further embodiment of the present invention, a laminate door is provided. The laminate door comprises a cement layer and a magnesium oxide layer.
Alternatively, the laminate door further comprises a frame, wherein the frame is placed around the edge of the building board.
Alternatively, the frame comprises metal, wood or plastics.
In a further embodiment of the present invention, a laminate flooring is provided. The laminate flooring comprises cement layer and wooden layer.
In a further embodiment of the present invention, a method for manufacturing the building board provided. The method comprises the steps of: providing a cement board and a magnesium oxide board; dehydrating the cement board and the magnesium oxide board; and binding the cement board and the magnesium oxide board.
The building board of the present invention utilizes cement layer as the surface, which significantly improves its duration. The building board of the present invention has features of moisture proofing, mould and fungus proofing, erode proofing, fireproofing, soundproofing and free of deformation. Moreover, since the use of wood can be reduced, the building board of the present invention reduces the influence to the natural environment effectively.
Furthermore, the use of magnesium oxide board further improves the performance of the building board. Compared with the conventional wooden building boards, the building board of the present invention has better flexibility, and easier to cut.
These and other features of the present invention will be elucidated in the following embodiments of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

Features, objects and advantages of the present invention can be easily understood with the reference to detailed description of the non-limiting embodiments taken in conjunction with the accompanying drawings, in which:

FIG. 1 illustrates a cross section view of a building board according to an embodiment of the present invention;

FIG. 2 illustrates a cross section of a building board according to another embodiment of the present invention;

FIG. 3 illustrates an overview of a laminate flooring according to a further embodiment of the present invention;

FIG. 4 illustrates a laminate door according to a further embodiment of the present invention;

FIG. 5 illustrates a flowchart of a method for manufacturing the building board according to an embodiment of the present invention;

FIG. 6 illustrates a cross section of a laminate flooring according to a further embodiment of the present invention.

DETAILED DESCRIPTION OF EMBODIMENTS

The embodiments of the present invention are discussed in details below with reference to the accompanying drawings.
FIG. 1 illustrates a cross section view of a building board according to an embodiment of the present invention. The building board comprises a cement layer 102 and a magnesium oxide layer 104. In practical applications, the building board can be used as laminate flooring, or laminate door of kitchen, cupboard and the like.
When the building board is installed on the ground as laminate flooring, the magnesium oxide layer 104 is positioned close to the ground, for example, on a cement floor or brick floor, and the cement layer 102 is positioned away from the ground. Therefore, with reference to the ground, the building board comprises the cement layer 102 and the magnesium oxide layer 104 in a top-down order. In an embodiment, the cement layer 102 and the magnesium oxide 104 are bound together with glue.
Compared with the wooden inner layer of the conventional wooden building boards, the magnesium oxide layer 104 of the building board of the present invention has better flexibility. The magnesium oxide layer 104 has features of nice moisture proofing, mould and fungus proofing, erode proofing, fireproofing, and free of deformation. Moreover, the magnesium oxide layer 104 also has the feature of soundproofing, and therefore the overall soundproof ability of the building board is improved. Thus, this building board is suitable for flooring pavement in storied buildings, or building doors such as kitchen door and the like.
The cement layer 102 of the building board may comprise cement and glass fiber. The density of the cement layer 102 can be precisely controlled by adjusting the composition of the cement and glass fiber. In an embodiment, the cement layer 102 has a density of 1.1 to 1.8 g/cm³. Furthermore, since the cement layer 102 has a hard surface and is not easy to wear out, and it also has features of nice moisture proofing, mould and fungus proofing, erode proofing, fireproofing, and free of deformation, and therefore the building board of the present invention is more durable compared with conventional building boards using wooden material.
In practical applications, the capability of moisture proofing and anti-deformation of the building board changes with the thickness of the cement layer 102 and the magnesium oxide layer 104. In a specific embodiment, the cement layer 102 has a thickness from 2 to 20 millimeters. In another embodiment, the magnesium oxide layer 104 has a thickness from 8 to 15 millimeters. Such configuration in thickness ensures that the building board has perfect performance of anti-deformation and soundproofing. Moreover, since wood which is currently used with huge consumption has been substituted by the cement layer 102 and the magnesium oxide layer 104, the building board of the present invention reduces the influence on the natural environment with cheaper manufacturing costs.
Preferably, the building board of the present invention can further comprise a heating device. For example, the heating device is configured outside the magnesium oxide 104. Since heat coming from the heating device can spread easily and fast through the magnesium oxide layer 104 and up into the room, and the magnesium oxide layer 104 can also keep warm longer, the magnesium oxide layer 104 is better for floor heating
FIG. 2 illustrates a cross section view of a building board according to another embodiment of the present invention. The building board comprises a cement layer 202, a magnesium oxide layer 204 and a buffer layer 206, wherein the buffer layer 206 is connected to the magnesium oxide layer 204.
In an embodiment, the buffer layer 206 comprises plastics or rubber, therefore the laminate floor is elastic and comfortable for walking on. Moreover, the buffer layer 206 makes the magnesium oxide layer 204 of the building board perfectly fit to the installing surface, such as the ground, and therefore the soundproofing performance of the building board is significantly improved.
FIG. 3 illustrates a top view of a laminate flooring according to a further embodiment of the present invention. As described in FIG. 3, the laminate flooring is shaped as regular hexagon. In other embodiments, the laminate flooring can also be shaped as square, rectangle, parallelogram, octagon and so on.
In practical applications, different pieces of laminate flooring can joint together. In an embodiment, each side of the laminate flooring may have a connecting structure such as tongue or groove to joint to each other. In other embodiments, the laminate flooring can have click system to joint to each other, such as single click system or double click system. In a preferred embodiment, the surface of the laminate flooring is covered with a protective coating such as varnish or oil, which can ease the connection and provide further protection to the laminate flooring. In some embodiments, the oil used as the protective coating comprises natural oil or mineral oil. In practical applications, the oil coated on the surface of the laminate flooring may at least partially permeate into the surface of the laminate flooring and mix with the cement or other materials in the laminate flooring. The mixing of the oil and the cement flooring forms a specific surface, which is much stronger and more resistant to chemicals and physical scratches.
It should be understood that the present invention is not limited to the connection manner between different pieces of the laminate flooring.
FIG. 4 illustrates a laminate door according to a further embodiment of the present invention. The laminate door can be used as kitchen door, cupboard door and the like. The laminate door comprises the building board illustrated in FIG. 1 or 2.
In FIG. 4, the laminate door further comprises a frame 408, which is placed around the edge of the building board. Optionally, the frame 408 can comprise metal, wood or plastics.
In some other examples, the building board depicted in FIG. 1 may also be used for lampshades or housings for receiving lamps. The lampshades or housings may have openings for leaking light out. As the building board of the present invention has features of erode proofing, fireproofing and free of deformation, the lampshades or housings made of the building board is more durable. It should be understood that the previous embodiments for applying the building board of the present invention are merely illustrative and are not limited.
FIG. 5 illustrates a flowchart of a method for manufacturing the building board according to an embodiment of the present invention.
In step S502, provides a cement board and a magnesium oxide board.
Specifically, the cement board can be made from cement and glass fibers mixed in a predetermined ratio. The magnesium oxide board can be made from magnesium oxide powder, glass fibers and/or wooden fibers mixed in a predetermined ratio.
In step S504, dehydrates the cement board and the magnesium oxide board.
Specifically, the cement board and the magnesium oxide board can be kept in a balance room, where the temperature and the humidity can be precisely controlled. In an embodiment, the magnesium oxide board and the cement board can be kept in the balance room for 2-3 weeks, so as to lower the water in the cement board and the magnesium oxide board down to 10-15% by mass.
In step S506, binds the cement board and the magnesium oxide board.
In an embodiment, step S506 further comprises binding the cement board and the magnesium oxide board by cold pressing. The process time of the cold pressing is 6 to 10 hours, and the pressure is 5 kg/cm². Optionally, the cement board and the magnesium oxide board can be bound with WBP (Water Boiled Proof) glue such as melamine glue and phenolic aldehyde glue. WBP glue has features of water proofing and water boiled proofing, which can effectively ensure the binding of the cement board and the magnesium oxide board.
In an embodiment, after step S506, the method further comprises binding buffer material to the magnesium oxide board. That is, the buffer material adheres to the side of the magnesium oxide board far away from the cement board. Further, the buffer material can be bound to the magnesium oxide board with WBP glue. Optionally, the buffer material can be plastics or rubber.
In an embodiment, after step S506 or the step of binding buffer material, the method further comprises cutting the bound cement board and magnesium oxide board. Based on different applications, the building board can be separated as different sizes.
In an embodiment, after the step of cutting the building board, the method further comprises forming a tongue or groove at each side of the building board, or forming a click system at each side of the building board.
In an embodiment, after the step of cutting the building board, the method further comprises coating a protective coating over the cement board, such as oil, varnish or other comparable materials. Optionally, coloring materials can be added into the protective coating so as to improve the decorative effect of the building board.
FIG. 6 illustrates a cross section of a laminate flooring according to a further embodiment of the present invention. As shown in FIG. 6, the laminate flooring comprises cement layer 602 and wooden layer 604. When the laminate flooring is installed on the ground, the wooden layer 604 is positioned close to the ground, for example, on a cement floor or brick floor, and the cement layer 602 is positioned away from the ground. Therefore, with reference to the ground, the laminate flooring comprises the cement layer 602 and the wooden layer 604 in a top-down order.
In an embodiment, the cement layer 602 and the wooden layer 604 are bound together with glue. Optionally, the cement layer 602 and the wooden layer 604 can be bounded with WBP (Water Boiled Proof) glue, such as melamine glue and phenolic aldehyde glue. The WBP glue has features of water proofing and water boiled proofing, which can ensure the binding of the cement layer 602 and the wooden layer 604.
The cement layer 602 of the laminate flooring may comprise cement and glass fibers. The density of the cement layer 602 can be precisely controlled by adjusting the composition of the cement and the glass fiber. In an embodiment, the cement layer 602 has a density of 1.1 to 1.8 g/cm³. Alternatively, the cement layer 602 has a thickness from 2 to 20 millimeters. The cement layer 602 features moisture proofing, mould and fungus proofing, erode proofing, fire proofing, and free of deformation.
In an embodiment, the laminate flooring further comprises a butter layer which is connected to the wooden layer 604. Specifically, the buffer layer is connected to one side of the wooden layer 604 far away from the cement layer 602. The buffer layer comprises rubber or plastics materials, which has good elasticity, and therefore the laminate flooring has better performance on sound proofing.
In an embodiment, the laminate flooring can be covered with protective coating, for example, oil or varnish, so as to protect the cement layer 602.
In an embodiment, the laminate flooring can be shaped as square, rectangle, parallelogram, hexagon, octagon and so on, and each side of the laminate flooring can have a connecting structure such as tongue or groove for the ease of connection. In another embodiment, the laminate flooring can use click systems to joint to each other, such as single click system or double click system. It should be understood that the present invention is not limited to the connection manner.
Although the present invention has been described above in the accompanying drawings and detailed descriptions, it should be understood that such descriptions are merely illustrative and are not limited; the present invention is not limited to such embodiments. Those skilled in this art may understand and implement other variations from the disclosed embodiments by studying the specification, disclosed contents, accompanying drawings and appended claims.

Claims

1-36. (canceled)

37. A laminate flooring building board comprising:

a cement board as a top layer; and

a magnesium oxide board as a lower layer, wherein the cement board and magnesium oxide board are bound to one another with a glue, wherein each side of the laminate flooring building board has at least one of a tongue and groove, and wherein the surface of the laminate flooring building board is covered with a protective coating of oil which permeates into the surface of the laminate flooring building board and mixes with cement of the cement board.

38. The laminate flooring building board of claim 37, wherein the top layer cement board comprises cement and glass fiber.

39. The laminate flooring building board of claim 37, wherein the top layer cement board has a thickness from 2 to 20 millimeters, wherein the lower layer magnesium oxide board has a thickness from 8 to 15 millimeters, and wherein the cement board has a density from 1.1 to 1.8 g/cm³.

40. The laminate flooring building board of claim 37, further comprising a buffer layer, wherein the buffer layer is connected to the magnesium oxide board, and wherein the buffer layer preferably comprises at least one of rubber and plastic.

41. The laminate flooring building board of claim 37, wherein the laminate flooring building board is shaped as one of a square, a rectangle, a parallelogram, a hexagon and an octagon.

42. A method for manufacturing a laminate flooring building board, the method comprising:

dehydrating a cement board and a magnesium oxide board;

binding the cement board to the magnesium oxide board with a glue, wherein the cement board is a top layer and the magnesium oxide board is a lower layer, providing each side of the laminate flooring building board with at least one of a tongue and a groove; and

covering the surface of the laminate flooring building board with a protective coating of oil, wherein the oil permeates into the surface of the laminate flooring building board and mixes with the top layer cement board.

43. The method of claim 42, wherein the dehydrating step further comprises dehydrating water in the cement board and the magnesium oxide board to 10-15% by mass.

44. The method of claim 42, wherein the binding step further comprises binding the cement board to the magnesium oxide board by cold pressing, and wherein a process time of the cold pressing is 6 to 10 hours, and a pressure of the cold pressing is 5 kg/cm².

45. The method of claim 42, wherein the cement board and the magnesium oxide board are bound with water boiled proof (WBP) glue.

46. The method of claim 42, further comprising binding a buffer material to the magnesium oxide board, wherein the buffer material comprises at least one of rubber and plastic.