BOARD AND METHOD FOR MANUFACTURING A BOARD

Abstract

A board consisting at least of a substrate formed at least of a gypsum-based and/or cement-based basic material layer. The board is provided with a chamfer extending through the basic material layer.

Claims

1. A panel, wherein the panel is a floor panel, a wall panel or a ceiling panel, wherein this panel comprises a basic material layer which is cement-based, wherein this panel comprises a top layer giving a decorative appearance to the panel, wherein the panel is provided with means which restrict moisture intake in the basic material layer, and/or with means which improve the internal bond in the basic material layer.

2. The panel of claim 1, wherein the aforementioned means which restrict the moisture intake in the basic material layer and/or the internal bond in the basic material layer, are applied at least in the proximity of the side of the basic material layer comprising said top layer and/or the side opposite thereto.

3. The panel of claim 2, wherein the means which restrict the moisture intake and/or the internal bond are at least applied at the respective surface of the basic material layer and/or directly thereunder.

4. The panel of claim 1, wherein the aforementioned means which restrict the moisture intake in the basic material layer and/or the internal bond in the basic material layer, are applied almost exclusively or exclusively in the proximity of the side of the basic material layer comprising said top layer and/or the side opposite thereto, whereas the respective means are not or almost not present in the middle of the basic material layer.

5. The panel of claim 1, wherein the aforementioned means which restrict the moisture intake in the basic material layer and/or the internal bond in the basic material layer, are applied over the entire thickness of the basic material layer.

6. The panel of claim 1, wherein the aforementioned means are of such a nature that they, at least on or next to a surface of the basic material layer, and preferably at least at the side where a top layer or backing layer is to be provided, seen in the thickness of the panel, provide for a zone which is alkaline-resistant and/or the alkaline resistance of which is improved.

7. The panel of claim 1, wherein the aforementioned means are of such a nature that they, at least on or next to a surface of the basic material layer, and preferably at least at the side where a top layer or backing layer is to be provided, a reaction with water from the atmosphere and/or from the basic material layer takes place.

8. The panel of claim 1, wherein the aforementioned means make use of a means which enhances hydrophobicity, which means is incorporated into the cement-based basic material layer at least on or next to the surface thereof.

9. The panel of claim 1, wherein the aforementioned means make use of a means which forms a filler and/or matrix of material which is water-impervious and/or water-repellent.

10. The panel of claim 1, wherein the aforementioned means provide for the application of a silane- and/or siloxane-containing liquid, more particularly emulsion.

11. The panel of claim 1, wherein the aforementioned means consist in adding so-called metal soaps to the material of the basic material layer.

12. The panel of claim 1, wherein the aforementioned means consist in adding, an additive, respectively, of hydrophobic powder, of silicates with hydrophobic features.

13. The panel of claim 1, wherein the aforementioned means comprise application of polyurethane is applied; wherein this polyurethane preferably is applied together with a crosslinker as adhesion promoter.

14. The panel of claim 1, wherein the aforementioned means provide for a reduction of the porosity of the basic material layer and/or a reduction of the capillary effect thereof and/or an increase of the density thereof.

15. The panel of claim 1, wherein the aforementioned means comprise applying one or more of the following chemical products in the basic material layer: acrylic and metacrylic (co)polymers, PVA or EVA polymers, styrene/acrylic acid ester copolymers, silane or siloxane of silicone.

16. The panel according to claim 1, wherein said top layer provides in a coating, either lacquer and/or print and/or layer adhered thereto, wherein the basic material layer, apart from the cement, also comprises fibers and/or fillers and/or filling agents, preferably additionally to possible process fibers, wherein these fillers and/or fibers preferably consist of synthetic material and/or glass and/or crystalline calcium silicate (including hydrate) and/or xonolite and/or tobermorite and/or inosilicate and/or gyrolite and/or wollastonite and/or sepiolite and/or rhyolite and/or basalt and/or rock wool and/or diabase and/or pumice and/or chalk and/or limestone and/or talc, wherein in the case of application as a particle-shaped filler, this filler preferably comprises particles which are comprised between 1 and 200 microns and/or this filler preferably forms at least 10 percent by weight of the dry cement mixture.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0134] FIG. 1 schematically represents a preferred embodiment of such board 1, wherein it is attached as a wall covering board or wall panel against a lath structure 2.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS OF THE INVENTION

[0135] The basic material layer 3 is a gypsum or fiber cement board. On top of this, a DPL layer 4 is pressed, which as such comprises one or more resin-impregnated sheets. Possibly, a counter layer 5 is provided. Compressing usually is performed at an increased temperature.

[0136] The coupling means 6 preferably are of the type which locks in two directions D1 and D2, as indicated. Preferably, they are also of the type which allows joining by means of a turning movement R.

[0137] As represented, herein preferably use is made of a longer rearmost lip 7, which is provided with a locking element 8.

[0138] At the front corner edge a chamfer 9 can be provided.

[0139] A preferably strip-shaped element 10, preferably provided at the locking element 8, can result in a pretension and/or result in a seal and/or result in a heat-activatable fire-retarding joint.

[0140] A recess 11 offers space for the head of a nail or the like, such that the whole is nailable or screwable.

[0141] Of course, the present invention is not limited to the example represented in the FIGURE.

[0142] Also, the FIGURE is schematically illustrative for floor panels, wherein then the back side of the represented panel has to be understood as underside. Locking coupling parts and other characteristics, such as chamfers 9, can be employed analogous in floor panels.

[0143] The most intended applications of the invention are floor panels and wall panels. With wall panels, this preferably are room-high panels which are provided with coupling parts at their edges, which edges are to be mounted vertically, said coupling parts being, for example, of the type as represented in the accompanying FIGURE. With floor panels, this preferably relates to smaller panels, which are provided at their four edges with coupling parts allowing a mutual coupling and locking, in order to be able to form, as usual, a so-called floating floor covering. Wall panels of fiber cement have the great advantage to be fire-resistant, whereas floor panels of this material will hardly expand as a result of temperature changes and the like.

[0144] The invention also relates to the obtained substrates as such, without these being already finished further by means of top layers or the like.

[0145] It is noted that all information comprised in WO 2018/138273 also has to be understood as incorporated in the present application, as alternative possibilities in combination with the herein above-described possibilities of the present application.

[0146] According to another preferred embodiment, the coupling parts are provided with a waterproof or moisture-repelling substance.

[0147] In a particular embodiment, the invention relates to a board, more particularly a panel in the form of a floor panel and/or wall panel and/or ceiling panel, preferably of the type which is at least intended for interior application, wherein this panel comprises a basic material layer or substrate which is cement-based, which basic material layer as such can comprise one or more layers of cement-based basic material, wherein one or more of these layers and preferably the entire basic material layer preferably is on the basis of fiber cement, wherein this panel comprises a top layer which comprises one or more synthetic material layers, which, at least in their entirety, have a thickness of 0.5 and still better 1 mm. This can be a vinyl-based layer, such as with LVT. In this manner, delamination in the fiber cement is avoided as the top layer then is sufficiently strong.

[0148] Alternatively, the top layer can also be a HPL layer glued onto the basic material layer. Such HPL layer provides for a strong surface, and delamination is almost excluded.