A composite board, furniture and door panel

Abstract

This invention provides a composite board, furniture, and door panel. The composite board includes a substrate and a ceramic substrate. The substrate has a first surface and a second surface. The ceramic slab is attached to the first surface of the substrate. The ratio of the water absorption thickness expansion rate of the substrate to that of the ceramic slab is in the range of 0.05 to 20. Because the ceramic slab is attached to the surface of the substrate, it can prevent scratches or cracks from appearing on the surface of the composite board. Furthermore, since the ratio of the water absorption thickness expansion rate of the substrate to that of the ceramic slab is in the range of 0.05 to 20, that is, the ratio of the water absorption thickness expansion rate of the substrate and the ceramic slab is small, it can avoid the composite board from delamination and breakage caused by cooling water during the cutting process.

Description

Technical Field

[0001] This invention belongs to the field of panel technology, specifically relating to a composite panel, furniture, and door panel. Background Technology

[0002] As living standards improve, people's demands for quality of life are also increasing. For furniture, people not only require aesthetically pleasing materials but also high-quality boards. To meet customer needs, furniture manufacturers have developed various styles of composite boards to simultaneously satisfy both aesthetic and quality requirements. One commonly used composite board is a wood-based panel and ceramic-ceramic composite board, where a ceramic veneer is covered on the surface of a wood substrate to achieve both. However, in wood-based panel and ceramic-ceramic composite boards, the ceramic veneer is brittle and unsuitable for machining to cut into various shapes to suit furniture needs. Even if cutting tools are used to cut the ceramic veneer, the difference in expansion coefficients between the wood substrate and ceramic veneer after water absorption during the cutting process often leads to delamination of the wood substrate and ceramic veneer during cutting, causing the composite board to break. Summary of the Invention

[0003] In order to overcome the shortcomings of the prior art, the present invention provides a composite board to solve the problems of poor processing performance of the existing wood and ceramic composite boards, and the easy delamination of the wood substrate and ceramic panel caused by the wood substrate absorbing water during the water-cooled cutting process.

[0004] One embodiment of the present invention provides a composite board, comprising: a substrate having a first surface and a second surface; and a ceramic slab attached to the first surface of the substrate; wherein the ratio of the water absorption thickness expansion rate of the substrate to the water absorption thickness expansion rate of the ceramic slab is in the range of 0.05 to 20.

[0005] In one embodiment, the composite panel further includes a first adhesive layer disposed between the substrate and the ceramic slab.

[0006] In one embodiment, the composite panel further includes a backing plate attached to the second surface of the substrate.

[0007] In one embodiment, the composite board further includes a second adhesive layer disposed between the substrate and the liner.

[0008] In one embodiment, the material used to make the first adhesive layer and / or the second adhesive layer includes a reactive polyurethane hot melt adhesive material.

[0009] In one embodiment, the thickness of the substrate is in the range of 9 to 40 mm; and / or, the thickness of the ceramic slab is in the range of 1 to 6 mm.

[0010] In one embodiment, the thickness ratio of the ceramic slab to the liner is n:1, where n is in the range of 2 to 10.

[0011] In one embodiment, a first surface of the substrate is provided with an adhesive-laying groove, and the first adhesive layer is partially accommodated in the adhesive-laying groove.

[0012] In one embodiment, the adhesive spreading groove has a wavy structure, the wave height of the adhesive spreading groove is in the range of 0.8 to 1.2 mm, and the wavelength of the adhesive spreading groove is in the range of 1.2 to 1.8 mm.

[0013] In one embodiment, the adhesive spreading groove includes a plurality of linear grooves arranged in parallel with each other;

[0014] And / or, the adhesive spreading groove includes a plurality of annular grooves, the size of which gradually increases from the inside to the outside; and / or, the adhesive spreading groove includes a plurality of grooves, in which the first adhesive layer is partially accommodated.

[0015] In one embodiment, the substrate is a straw board.

[0016] In one embodiment, the water absorption thickness swelling rate of the straw board is less than or equal to 0.6%; and / or, the water absorption thickness swelling rate of the composite board is less than or equal to 0.1%; and / or, the water absorption length change rate or water absorption width change rate of the straw board is less than or equal to 0.4%.

[0017] In one embodiment, the ratio of the water absorption rate of the straw board to the water absorption rate of the ceramic rock board is in the range of 0.05 to 20.

[0018] In one embodiment, the water absorption rate of the straw board is less than or equal to 0.5%; and / or, the water absorption rate of the ceramic rock board is less than or equal to 0.05%; and / or, the water absorption rate of the composite board is less than or equal to 0.1%.

[0019] In one embodiment, the nail-holding force of the composite board is greater than or equal to 12 N / mm². 2 ; and / or, the edge holding force of the composite board is greater than or equal to 8 N / mm 2 .

[0020] In one embodiment, the fire resistance of the composite panel includes: the fire growth rate of the composite panel is less than or equal to 250W / s;

[0021] And / or, the flame spread range on the side of the composite plate is less than or equal to the edge of the composite plate; and / or, the total heat release of the composite plate in the first 600 seconds when exposed to the burner flame is less than or equal to 15 MJ.

[0022] In one embodiment, the formaldehyde emission of the composite panel is less than or equal to 0.06 mg / m³. 3 .

[0023] In one embodiment, the density of the straw board is between 0.4 and 0.8 g / cm³. 3 Within the range.

[0024] In one embodiment, the substrate is a foamed aluminum board.

[0025] In one embodiment, the aluminum foam board has a closed-cell structure; and / or, the porosity of the aluminum foam board is in the range of 80% to 90%; and / or, the pore size of the aluminum foam board is in the range of 0.4 to 5 mm.

[0026] In one embodiment, the ratio of the coefficient of thermal expansion of the aluminum foam board to that of the first ceramic rock board is in the range of 0.2 to 5.

[0027] In one embodiment, the thickness of the aluminum foam plate is in the range of 12 to 40 mm; and / or, the thickness of the first ceramic slab is in the range of 3 to 6 mm.

[0028] In one embodiment, the nail-holding force of the composite board is greater than or equal to 10 N / mm². 2 .

[0029] In one embodiment, the liner includes a second ceramic slab; and / or, the thickness of the liner is less than or equal to the thickness of the first ceramic slab.

[0030] In one embodiment, the first surface of the aluminum foam board has a porous structure, and the first adhesive layer is partially disposed in the porous structure.

[0031] In one embodiment, the density of the aluminum foam board is between 0.2 and 0.4 g / cm³. 3 Within the range.

[0032] Another embodiment of the present invention provides furniture, including a composite board. The composite board is any of the composite boards described in the preceding embodiments.

[0033] Another embodiment of the present invention provides a door panel, including a composite panel. The composite panel is the composite panel described in any of the above embodiments.

[0034] In one embodiment, the door panel further includes an edge banding strip attached to the outer periphery of the door panel.

[0035] In one embodiment, the edge banding strip includes an outer layer, which is an aluminum sheet, an aluminum alloy sheet, or an ABS plastic sheet.

[0036] In one embodiment, the edge banding strip further includes a PVC adhesive layer, which is disposed on the side of the outer surface layer that is attached to the outer periphery of the door panel.

[0037] The composite panels, furniture, or door panels provided in the above embodiments of the present invention have the following beneficial effects:

[0038] 1. Because the substrate surface is coated with ceramic slabs, these slabs enhance the aesthetics and strength of the board surface, allowing for greater diversity in surface styles and satisfying the aesthetic needs of different groups, thereby highlighting the luxury and high-end nature of the furniture. Furthermore, the high hardness and wear resistance of the ceramic slabs effectively prevent scratches or cracks on the board surface, resulting in better stability of the composite board.

[0039] 2. Because the ratio of the water absorption thickness expansion rate of the substrate to that of the ceramic slab is within the range of 0.05 to 20, the difference in mechanical properties between the substrate and the ceramic slab is small, thus avoiding delamination between the substrate and the ceramic slab during long-term use and resulting in composite panel damage. In particular, during the cutting process of the composite panel, even if the ceramic slab requires water spraying for cooling or dust removal, the low water absorption thickness expansion rate of the substrate makes it less likely for delamination between the substrate and the ceramic slab to occur during cutting, thus preventing composite panel damage.

[0040] 3. Because a backing plate is attached to the other surface of the substrate, the backing plate can effectively protect the substrate and prevent corrosion. In particular, since one surface of the substrate is covered by a ceramic slab and the other surface is covered by a backing plate, this arrangement can further improve the waterproof performance of the composite board, thereby further preventing the composite board from delaminating and breaking during use or cutting due to the difference in water absorption and expansion rates between the substrate and the ceramic slab.

[0041] 4. The substrate is bonded to the ceramic slab and the liner plate via a first adhesive layer and a second adhesive layer, respectively. The first or second adhesive layer can be made of PUR hot melt adhesive. Since PUR hot melt adhesive does not contain organic solvents, it can be applied at a lower temperature. Initial bonding is achieved after cooling and solidification following adhesive application. In subsequent processes, the PUR hot melt adhesive undergoes moisture curing in air, resulting in excellent bond strength and impact resistance after complete curing. Therefore, the composite panel formed by bonding the substrate to the ceramic slab and the liner plate using PUR hot melt adhesive exhibits high bonding strength.

[0042] 5. In one embodiment, the substrate is made of strawboard. The strawboard can effectively improve the nail-holding power of the composite board, thereby improving the machinability of the resulting composite board. Furthermore, the density of the strawboard is set between 0.4 and 0.8 g / cm³. 3 Within this range, it can be ensured that the manufactured composite board has high nail-holding power while its overall weight is not excessive. In one embodiment, straw board is used as the base material, and after being combined with ceramic rock slab, the nail-holding power of the composite board is greater than or equal to 12 N / mm². 2 The holding force of the composite board at its edge is greater than or equal to 8 N / mm. 2 Furthermore, the composite board has good fire resistance and low formaldehyde emission. Therefore, the composite board made from straw board and ceramic rock slab is particularly suitable for furniture making.

[0043] 6. In one embodiment, the substrate is made of aluminum foam board. Because aluminum foam board is relatively stable and its dimensional change rate after absorbing water is small, the composite board made by combining it with ceramic slab has good machinability. During the cutting process of the composite board, even if the ceramic slab needs to be cooled or dusted by spraying water, the dimensions of the aluminum foam board remain largely unchanged after absorbing water. Therefore, the composite board is less prone to delamination between the aluminum foam board and the ceramic slab during cutting, which could lead to damage.

[0044] 7. Using aluminum foam board as the base material for composite boards can improve the nail-holding power of the resulting composite boards. Because aluminum foam board has many irregularly sized pores, when a screw penetrates into the interior of the aluminum foam board, the inner walls of these irregularly sized pores can hold the screw, thus effectively improving the nail-holding power of the aluminum foam board.

[0045] 8. Using aluminum foam board as the substrate of the composite board effectively reduces the weight of the composite board due to its low density and light weight. In one embodiment, the density of the aluminum foam board is set between 0.2 and 0.4 g / cm³. 3Within the specified range, the density of the aluminum foam board should be set between 0.2 and 0.4 g / cm³. 3 Within this range, it can be ensured that the composite board has high nail-holding power without being too heavy. In this case, composite boards made of aluminum foam and ceramic slabs are particularly suitable for manufacturing door panels.

[0046] 9. The aluminum foam board has a closed-cell structure. By setting the aluminum foam board to a closed-cell structure, the nail-holding force of the aluminum foam board can be further improved, and its machinability can be enhanced. In addition, selecting aluminum foam boards with pore sizes in the range of 0.4 to 5 mm can also improve the nail-holding force of the aluminum foam board due to the smaller pore size.

[0047] 10. When using aluminum foam board as the substrate of the composite board, the pore structure on the surface of the aluminum foam board can increase the contact area between the first adhesive layer and the aluminum foam board when the first adhesive layer is used to bond the aluminum foam board and the ceramic rock board, thereby improving the bonding performance between the aluminum foam board and the ceramic rock board. Attached Figure Description

[0048] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on the structures shown in these drawings without creative effort.

[0049] Figure 1 This is a schematic diagram of the structure of the composite plate provided in an embodiment of the present invention;

[0050] Figure 2 This is a schematic diagram of the structure of a straw board provided in another embodiment of the present invention;

[0051] Figure 3 for Figure 2 A top view of the straw board;

[0052] Figure 4 for Figure 2 A schematic diagram of the structure of the straw board after attaching ceramic rock slabs and lining plates;

[0053] Figure 5 This is a schematic diagram of the structure of a straw board provided in another embodiment of the present invention;

[0054] Figure 6 This is a schematic diagram of the structure of a straw board provided in another embodiment of the present invention;

[0055] Figure 7 This is a schematic diagram of the structure of a composite plate provided in another embodiment of the present invention;

[0056] Figure 8 for Figure 7 A schematic diagram of the porous structure on the surface of the foamed aluminum plate;

[0057] Figure 9 for Figure 7 A schematic diagram of the porous structure when adhesive-laying grooves are set on the surface of the foamed aluminum sheet;

[0058] Figure 10 This is a schematic diagram of the structure of a door panel provided in another embodiment of the present invention;

[0059] Figure 11 for Figure 10 An enlarged schematic diagram of area A of the door panel. Detailed Implementation

[0060] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0061] It should be noted that if the embodiments of the present invention involve directional indicators (such as up, down, left, right, front, back, etc.), the directional indicators are only used to explain the relative positional relationship and movement of the components in a specific posture. If the specific posture changes, the directional indicators will also change accordingly.

[0062] Furthermore, if the embodiments of this invention involve descriptions such as "first" or "second," these descriptions are for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined with "first" or "second" may explicitly or implicitly include at least one of those features. Additionally, the use of "and / or" or "and / or" throughout the text includes three parallel solutions. For example, "A and / or B" includes solution A, solution B, or a solution where both A and B are satisfied simultaneously. Furthermore, the technical solutions of the various embodiments can be combined with each other, but this must be based on the ability of those skilled in the art to implement them. When the combination of technical solutions is contradictory or impossible to implement, it should be considered that such a combination of technical solutions does not exist and is not within the scope of protection claimed by this invention.

[0063] Please see Figure 1 One embodiment of the present invention provides a composite board 100, including a substrate 110 and a ceramic slab 120.

[0064] The substrate 110 has a first surface 111 and a second surface 112.

[0065] The ceramic slab 120 is attached to the first surface 111 of the substrate 110.

[0066] The ratio of the water absorption thickness expansion rate of the substrate 110 to the water absorption thickness expansion rate of the ceramic slab 120 is in the range of 0.05 to 20.

[0067] In the composite panel 100 provided in this embodiment, since a ceramic slab 120 is attached to the surface of the substrate 110, the ceramic slab 120 can improve the aesthetics and strength of the panel surface, making the surface style of the panel more diverse, thereby meeting the appearance needs of different groups of people and highlighting the luxury and high-end level of the furniture. On the other hand, since the ceramic slab 120 itself has high hardness and good wear resistance, it can effectively prevent scratches or cracks from appearing on the panel surface, thus making the composite panel with good stability.

[0068] Furthermore, since the ratio of the water absorption thickness expansion rate of the substrate 110 to that of the ceramic slab 120 is within the range of 0.05 to 20, the difference in mechanical properties between the substrate 110 and the ceramic slab 120 is small. This avoids the phenomenon of delamination between the substrate 110 and the ceramic slab 120 during long-term use, which could lead to damage to the composite panel 100. In particular, during the cutting process of the composite panel 100, even if the ceramic slab 120 requires water spraying for cooling or dust removal, the low water absorption thickness expansion rate of the substrate 110 makes it less likely for delamination between the substrate 110 and the ceramic slab 120 to occur during the cutting process, thus preventing damage to the composite panel 100.

[0069] In this embodiment, the substrate 110 is a straw board. Straw board is a high-performance artificial composite board made from agricultural production residues such as wheat straw, corn stalks, sorghum stalks, rice straw, and sugarcane residue. This board is relatively environmentally friendly, waterproof, fireproof, and a renewable resource, aligning with the national policy for sustainable development in the manufacturing industry. Furthermore, straw board is relatively inexpensive, reducing the production cost of composite boards. In the actual manufacturing process of straw board, after removing impurities such as soil from the wheat straw raw material, it undergoes mechanical crushing, screening, drying, mixing, laying, rolling, edge sawing, and inspection to finally obtain the finished board. In this embodiment, the straw board 110 is made from grain biomass material, consisting of approximately 60% straw raw material and over 30% common salt and mineral oil composites, processed using high-temperature, high-pressure, and mechanical extrusion technology.

[0070] The ceramic slab 120 is attached to the first surface of the straw board 110. Ceramic slab (Porcelain Slab) refers to a new type of plate-shaped inorganic material made primarily from clay and other inorganic non-metallic materials. Through molding, drying, and high-temperature sintering, the resulting blank has a consistent color with the surface and can be processed according to design requirements through cutting, drilling, and polishing. Ordinary ceramic plates or sheets, due to their brittleness and low strength, are difficult to cut, drill, or perform other machining processes to meet the needs of various types of furniture. Ceramic slab, however, due to its high hardness and excellent impact and wear resistance, can be cut and drilled according to design requirements. Therefore, the composite board made from straw board 110 and ceramic slab 120 can also be cut, drilled, and polished as needed to meet the requirements of different types of furniture.

[0071] In the composite board 100 provided in this embodiment, since the interior of the composite board 100 uses straw board 110 as the base material, the straw board 110 can effectively improve the nail holding force of the composite board 100, thereby making the prepared composite board 100 easy to splice and assemble using screws.

[0072] Water absorption thickness swelling rate refers to the ratio of the thickness difference of a sample before and after water absorption to the original thickness after soaking in water for a specified period, measured according to a prescribed method. Due to frequent changes in air humidity and the potential for frequent contact between furniture boards and water, water absorption thickness swelling rate is an important evaluation factor for furniture boards. Generally, ceramic materials have relatively stable mechanical properties and a low water absorption thickness swelling rate. However, conventional wood boards tend to expand in size after absorbing water, resulting in a higher water absorption thickness swelling rate. The water absorption thickness swelling rate of typical wood boards may exceed 10%, while that of ceramic materials is generally less than 0.1%. The ratio of their water absorption thickness swelling rates is relatively large. Therefore, for composite boards made of conventional wood substrates and ceramic materials, due to the large ratio of their water absorption thickness swelling rates, the wood substrate and ceramic materials are prone to delamination after prolonged use, leading to damage to the composite board. In this embodiment, since the ratio of the water absorption thickness expansion rate of the straw board 110 and the ceramic rock board 120 is within the range of 0.05 to 20, it can avoid the phenomenon that the composite board 100 is damaged due to the delamination of the straw board 110 and the ceramic rock board 120 during long-term use.

[0073] In one embodiment, the density of the straw board 110 is set to be between 0.4 and 0.8 g / cm³. 3 Within the specified range, the density of straw board 110 is set between 0.4 and 0.8 g / cm³.3 Within this range, it can be ensured that while possessing high nail-holding power, the overall weight of the composite board 100 will not be excessive. For example, when the density of the straw board 110 is set to 0.4 g / cm³... 3 At this time, the composite board 100 has a relatively light overall weight, making it suitable for furniture side panels and door panels. While ensuring nail-holding power, the composite board 100 is also relatively easy to use. When the density of the straw board 110 is 0.8 g / cm³... 3 At this point, the overall quality of composite board 100 is improved, making it suitable for furniture tabletops. Composite board 100 is also thicker and safer, with improved load-bearing capacity.

[0074] In one embodiment, the composite board 100 further includes a liner 130. The liner 130 is attached to the second surface 112 of the straw board 110, opposite to the first surface 111. Specifically, the thickness ratio of the ceramic slab 120 and the liner 130 is n:1, where n ranges from 2 to 10. By attaching the liner 130 to the second surface 112 of the straw board 110, opposite to the first surface 111, the liner 130 effectively protects the straw board 110 from corrosion; furthermore, since the two surfaces of the straw board 110 are covered by the ceramic slab 120 and the liner 130 respectively, the waterproof performance of the composite board 100 is further improved. Therefore, during use, the composite board 100 is less likely to delaminate and break due to the difference in water absorption and expansion rates between the ceramic slab 120 and the straw board 110.

[0075] In this embodiment, the water absorption thickness expansion rate of the straw board 110 is less than or equal to 0.6%. Since the water absorption thickness expansion rate of the straw board 110 is less than or equal to 0.6%, it can be fully adapted to the water absorption thickness expansion rate of the ceramic slab 120. As needed, the water absorption thickness expansion rate of the composite board 100 is less than or equal to 0.1%. In one specific embodiment, the water absorption thickness expansion rate of the composite board 100 is 0.07%. Besides the water absorption thickness expansion rate, the water absorption dimension change rate in the length or width direction is also an important consideration for furniture boards. As needed, the water absorption length change rate or water absorption width change rate of the straw board 110 is less than or equal to 0.4%, thereby achieving adaptation to the ceramic slab 120. In this embodiment, the water absorption width change rate of the straw board 110 in the transverse direction is 0.37%; the water absorption length change rate of the straw board 110 in the longitudinal direction is 0.33%.

[0076] Understandably, the water absorption rates of the straw board 110 and the ceramic slab 120 also affect the waterproof performance of the composite board 100. In one embodiment, the ratio of the water absorption rate of the straw board 110 to that of the ceramic slab 120 is within the range of 0.05 to 20. Setting the ratio of the water absorption rates of the straw board 110 and the ceramic slab 120 to be within the range of 0.05 to 20 can also avoid delamination caused by the different dimensional changes of the straw board 110 and the ceramic slab 120 after water absorption. In this embodiment, the water absorption rate of the straw board 110 is less than or equal to 0.5%; the water absorption rate of the ceramic slab 120 is less than or equal to 0.05%. The water absorption rate of the composite board 100 is less than or equal to 0.1%.

[0077] In one embodiment, the thickness of the straw board 110 is in the range of 9 to 40 mm. The thickness of the ceramic slab 120 is in the range of 1 to 6 mm. The purpose of setting the thickness of the straw board 110 in the range of 9 to 40 mm is that, since the density of the straw board 110 is significantly lower than that of the ceramic slab 120, a thickness of approximately 9 to 40 mm can significantly reduce the overall weight of the composite board 100; simultaneously, setting the thickness of the straw board 110 to 9 to 40 mm also ensures that the resulting composite board 100 has high nail-holding power. In other words, when the thickness of the straw board 110 is in the range of 9 to 40 mm, the composite board 100 has high nail-holding power while maintaining a relatively light weight, making installation and transportation convenient and providing greater comfort in use. Generally, nail-holding power refers to the performance of wood in securing metal fasteners (nails, wood screws, etc.), calculated as the force required to pull out a screw of a certain size. As required, the holding force of the composite board 100 is greater than or equal to 12 N / mm. 2 The edge holding force of the composite board 100 is greater than or equal to 8 N / mm. 2 In one embodiment, the holding force of the composite board 100 is 12.7 N / mm. 2 The edge holding force of the composite board 100 is greater than or equal to 8.9 N / mm. 2 The test method is based on EN 13446 to 2002, and the test conditions are set as follows:

[0078] Screw size: ST4.2×38;

[0079] Pin removal speed: 5mm / min;

[0080] Sample size: 50mm × 50mm;

[0081] Test environment: 21.6℃, 64%RH.

[0082] It is evident that the composite board 100 provided in this embodiment of the invention has a high nail-holding force, which meets the needs of the furniture industry.

[0083] The purpose of setting the thickness of the ceramic slab 120 within the range of 1 to 6 mm is to allow it to adapt to the needs of different usage scenarios. When the composite board 100 is used on non-high load-bearing surfaces such as furniture side panels or door panels, a thinner ceramic slab 120 is sufficient. Conversely, when the composite board 100 is used on high load-bearing surfaces such as furniture countertops or cabinet panels, a thicker ceramic slab 120 is selected. In this embodiment, the thickness of the ceramic slab 120 is preferably 3 mm. At this thickness, the weight, wear resistance, and load-bearing capacity of the ceramic slab 120 are moderate, meeting the needs of most users. Furthermore, the production cost of the corresponding ceramic slab 120 is relatively low, and it offers strong overall performance.

[0084] In addition, the applicant also conducted fire resistance tests on the manufactured composite panel 100. In one embodiment, the fire resistance of the composite panel 100 includes:

[0085] The combustion growth rate of the composite plate 100 is less than or equal to 250 W / s;

[0086] And / or, the flame spread range on the side of the composite plate 100 is less than or equal to the edge of the composite plate 100;

[0087] And / or, the total heat release of the composite plate 100 in the first 600 seconds when exposed to the burner flame is less than or equal to 15 MJ.

[0088] Specifically, the standard document used in the fire resistance performance testing process is EN 13501 to 1:2018 Classification of fire performance of building materials and articles thereof. The specific test methods are as follows:

[0089] 1. EN 13823:2020 Burning tests on building articles to individual burning tests on building materials (excluding flooring materials);

[0090] 2. EN ISO 11925 to 2:2020 Burning test until building articles are ignited with a specified flame.

[0091] During the testing of the composite panel 100, the installation and fixing method of the composite panel 100 is determined according to the standard document: EN13823:2020. Specifically, the composite panel sample to be tested has no ventilation gap, stands freely upright, and the top and bottom ends of the composite panel 100 are fixed.

[0092] The test results are shown in the table below:

[0093]

[0094] in:

[0095] FIGRA refers to the combustion growth rate index [W / s] used for grading;

[0096] For grades A2 and B, FIGRA = FIGRA 0.2MJ ;

[0097] For Class C and Class D, FIGRA = FIGRA 0.4MJ ;

[0098] LFS refers to the lateral spread length of the flame [m];

[0099] THR 600s The total heat released over a period of 600 seconds [MJ];

[0100] SMOGRA refers to the flue gas formation rate [m]. 2 / s 2 ];

[0101] TSP 600s The total amount of flue gas generated over a period of 600 seconds [m] 2 ].

[0102] As required, the applicant also conducted RoHS directive tests on the manufactured composite panel 100. During the RoHS directive testing process, Pb / Cd / Hg / Cr6+ / PBBs / PBDEs and Phthalates tests were performed. The test methods referenced IEC 62321 to 4:2013+A1:2017, IEC 62321 to 5:2013, IEC 62321 to 7 to 2:2017, IEC 62321 to 6:2015, and IEC 62321 to 8:2017, employing ICP to OES, UV to Vis, and GC to MS for analysis.

[0103] The test results are shown in the table below:

[0104]

[0105]

[0106] in:

[0107] (1) 1 mg / kg = 0.0001%;

[0108] (2) MDL = Method detection limit;

[0109] (3)ND = Not detected (<MDL);

[0110] (4)"to" = Not specified.

[0111] It can be seen that the fabricated composite panel 100 can clearly meet the requirements of the RoHS directive item tests.

[0112] In one embodiment, in order to make the composite panel 100 meet the environmental protection requirements, the formaldehyde emission of the composite panel is less than or equal to 0.06 mg / m 3 , so as to avoid harm to human health. Accordingly, the applicant tested the formaldehyde emission of the fabricated composite panel. The test method referred to EN 717-1:2004 and used UV-Vis analysis. The test results showed that the formaldehyde emission of the composite panel 100 provided by the embodiment of the present invention was 0.050 mg / m 3 . In the standard of BS EN 13986:2004+A1:2015, when the formaldehyde emission ≤ 0.124 mg / m 3 , the sample reaches the E1 grade. It can be seen that the formaldehyde emission of the composite panel provided by the embodiment of the present invention is 0.050 mg / m 3 , which is significantly less than 0.124 mg / m 3 . Therefore, the fabricated composite panel reaches the E1 grade in the standard of BS EN 13986:2004+A1:2015.

[0113] In one embodiment, the composite panel 100 further includes a first adhesive layer 140 and a second adhesive layer 150.

[0114] The first adhesive layer 140 is disposed between the straw board 110 and the ceramic slab 120, for attaching the ceramic slab 120 to the straw board 110. The second adhesive layer 150 is disposed between the straw board 110 and the liner 130, for attaching the liner 130 to the straw board 110. Specifically, the liner 130 can be made of a metal plate or a ceramic slab. When the liner 130 is made of a ceramic slab, the material of the liner 130 can be the same as or different from the material of the ceramic slab 120. Furthermore, when the liner 130 is made of a ceramic slab, the thickness of the liner 130 is less than the thickness of the ceramic slab 120. In this embodiment, the liner 130 is made of a metal plate. The straw board 110 is a solid structure. The ceramic slab 120 is attached to the first surface 111 of the straw board 110 via a first adhesive layer 140; the liner 130 is attached to the second surface 112 of the straw board 110 via a second adhesive layer 150. Both the first adhesive layer 140 and the second adhesive layer 150 are reactive hot melt adhesive materials. It is understood that either the first adhesive layer 140 or the second adhesive layer 150 can also be set as a reactive hot melt adhesive material. In one embodiment, the reactive hot melt adhesive material is a reactive polyurethane (PUR) hot melt adhesive material. Because PUR hot melt adhesive materials do not contain organic solvents, they can be applied at lower temperatures. Initial bonding is achieved by cooling and solidification after adhesive application. In subsequent processes, the PUR hot melt adhesive material undergoes moisture curing in air, and after complete curing, it exhibits excellent bonding strength and impact resistance. Therefore, by bonding the straw board 110, ceramic rock board 120, and lining board 130 together with the reactive hot melt adhesive material, the resulting composite board 100 has high bonding strength.

[0115] In the specific bonding process, the curing process of PUR hot melt adhesive is divided into two stages: cooling and solidification, and moisture curing.

[0116] During the cooling and coagulation stage, PUR hot melt adhesive is heated and applied to the straw board. After the PUR hot melt adhesive cools and coagulates, it produces initial bonding strength.

[0117] During the moisture curing stage, the PUR hot melt adhesive undergoes a chain extension reaction with the moisture in the air to form a rigid structure of polyurethane molecular chains, thereby giving it high bonding strength, as well as good chemical resistance, heat resistance, and hydrolysis resistance.

[0118] Therefore, in this embodiment, the ceramic slab 120 and the liner 130 are respectively attached to the first surface 111 and the second surface 112 of the straw board 110 using reactive hot melt adhesive. The straw board 110, the ceramic slab 120, the liner 130, the first adhesive layer 140, and the second adhesive layer 150 are integrated into a composite board structure after being cured by heating and pressurizing.

[0119] In this embodiment, the liner 130 is made of aluminum alloy sheet. The thickness of the liner 130 is in the range of 0.2 to 0.8 mm. When the composite panel has a large volume during installation and requires a large load-bearing capacity, a larger thickness of 0.8 mm for the liner 130 can provide greater load-bearing capacity and make the installation more stable. Conversely, when the composite panel has a small volume during installation, a smaller thickness of 0.2 mm for the liner 130 is sufficient.

[0120] In one embodiment, the reactive hot melt adhesive is a PUR reactive hot melt adhesive. When attaching the ceramic slab 120 and the liner 130 to the straw board 110, the PUR reactive hot melt adhesive is first placed in a hot melt machine. After preheating, heating, and dispensing, the PUR reactive hot melt adhesive is applied to the surface of the liner 130 to form a second adhesive layer 150 with a thickness of 0.1 to 0.2 mm. Then, the straw board 110 is placed face-up over the second adhesive layer 150, and a first adhesive layer 140 with a thickness of 0.1 to 0.2 mm is applied to the upper surface (first surface 11) of the straw board 110. The ceramic slab 120 is then placed face-up over the second adhesive layer 150 to form a pre-finished composite board. The pre-finished composite board is then placed in a hot press for heating and pressure curing to form the finished composite board. During the manufacturing process, the PUR reactive hot melt adhesive is preheated at a temperature between 80 and 110°C, and heated at a temperature between 120 and 130°C. Excessive heating temperature can easily cause the PUR reactive hot melt adhesive to crack and carbonize, thus affecting its adhesive properties. In application, the composite board is cut to the required dimensions for furniture processing, and then the outer edges of the furniture board are sealed to provide comprehensive protection. Therefore, the composite board provided in this embodiment of the invention has fireproof, waterproof, and insect-proof characteristics. Furthermore, to improve the adhesion between the straw board 110 and the ceramic slab 120, a wavy adhesive-laying groove can be formed on the first surface of the straw board 110. Simultaneously, to save on the amount of PUR reactive hot melt adhesive used, the wave height of the adhesive-laying groove is controlled within the range of 0.8 to 1.2 mm, and the wavelength is controlled within the range of 1.2 to 1.8 mm. The adhesive-laying groove is integrally formed with the straw board 110 during manufacturing. When PUR reactive hot melt adhesive is applied to the straw board 110 with this structure, the PUR reactive hot melt adhesive partially sinks into the adhesive-laying groove, resulting in better fusion with the PUR reactive hot melt adhesive and thus a stronger adhesion between the straw board 110 and the ceramic slab 120. Furthermore, by strictly controlling the wave height and wavelength of the adhesive-laying groove, waste of PUR reactive hot melt adhesive can be effectively avoided, thereby controlling the production cost of the composite board provided in this embodiment of the invention. Simultaneously, the composite board of this invention has passed formaldehyde content testing and no formaldehyde was detected, classifying it as a zero-formaldehyde environmentally friendly board product.

[0121] In fact, during the preparation of the composite board 100, the applicant attempted to combine wood boards, PVC (Polyvinylchloride) boards, bamboo charcoal fiber boards, honeycomb aluminum boards, etc., with ceramic rock boards to make composite boards, but the overall performance of each was unsatisfactory.

[0122] For composite panels made of wood and ceramic slabs, on the one hand, the difference in water absorption and expansion coefficients between wood and ceramic slabs is significant, which can easily lead to delamination and damage to the composite panel after prolonged use; on the other hand, wood also has poor fire resistance.

[0123] For composite panels made of PVC and ceramic slabs, the significant difference in their water absorption and expansion coefficients can lead to delamination and damage after prolonged use. Furthermore, PVC sheets may undergo internal chemical reactions under sunlight, resulting in deterioration of the material's performance.

[0124] For composite panels made of bamboo charcoal fiberboard and ceramic slabs, the significant difference in their water absorption and expansion coefficients can lead to delamination and damage after prolonged use. Furthermore, bamboo charcoal fiberboard has poor fire resistance and contains lead, which can harm human health.

[0125] For composite panels made of honeycomb aluminum panels and ceramic slabs, on the one hand, the honeycomb aluminum panels have relatively low nail-holding power, and when screws are installed on the composite panels, the screws are prone to falling out of the composite panels. In addition, the manufacturing process of honeycomb aluminum panels is more complex, and the overall cost is also higher.

[0126] Therefore, it is evident that composite boards made from straw boards and ceramic rock slabs have superior overall mechanical, waterproof, fireproof, and environmental performance compared to composite boards made from wood boards, PVC boards, bamboo charcoal fiber boards, or honeycomb aluminum boards combined with ceramic rock slabs.

[0127] Example 2:

[0128] Please see Figure 2 and Figure 3 In one embodiment, the adhesive-laying groove includes a plurality of linear grooves 113. The plurality of linear grooves 113 are arranged in parallel. During the process of attaching the ceramic slab 120 to the straw board 110, the plurality of linear grooves 113 can reduce the relative displacement between the ceramic slab 120 and the straw board 110. If necessary, the surface of the ceramic slab 120 that is in contact with the straw board 110 can also be provided with linear protrusions 210 corresponding to the linear grooves 113 of the straw board 110. During the bonding process, the linear protrusions 210 of the ceramic slab 120 can be correspondingly accommodated in the linear grooves 113 of the straw board 110, thereby further reducing the relative displacement between the ceramic slab 120 and the straw board 110 during the bonding process. At this time, the resulting composite board is as follows: Figure 4 As shown.

[0129] Example 3:

[0130] Please see Figure 5 In one embodiment, the adhesive-laying groove includes a plurality of annular grooves 121. The dimensions of the plurality of annular grooves 121 gradually increase from the inside to the outside. Similarly, the purpose of configuring the adhesive-laying groove to include a plurality of annular grooves 121 is to reduce the relative displacement of the ceramic slab 120 relative to the straw board 110 in various directions during the bonding process. If necessary, the surface of the ceramic slab 120 that is bonded to the straw board 110 may also be provided with annular protrusions corresponding to the annular grooves 121 of the straw board 110. During the bonding process, the annular protrusions of the ceramic slab 120 can be correspondingly accommodated in the annular grooves 121 of the straw board 110, thereby further reducing the relative displacement of the ceramic slab 120 and the straw board 110 during the bonding process.

[0131] Example 4:

[0132] Please see Figure 6 In one embodiment, the adhesive-laying groove includes a plurality of grooves 131 disposed on a first surface 111 of the straw board 110. The reactive hot melt adhesive portion is embedded in the plurality of grooves 131. Similarly, the purpose of configuring the adhesive-laying groove to include a plurality of grooves 131 is to reduce the relative displacement of the ceramic slab 120 relative to the straw board 110 in various directions during the bonding process. If necessary, the surface of the ceramic slab 120 that is bonded to the straw board 110 may also be provided with protrusions corresponding to the grooves 131 of the straw board 110. During the bonding process, the protrusions of the ceramic slab 120 can be correspondingly accommodated in the grooves 131 of the straw board 110, thereby further reducing the relative displacement of the ceramic slab 120 and the straw board 110 during the bonding process.

[0133] Understandably, the sides of the straw board 110 and the ceramic rock slab 120 are also provided with edge sealing strips (not shown). The edge sealing strips cover the sides of the straw board 110 and the ceramic rock slab 120, thereby preventing moisture or other pollutants from entering the interior of the composite board 100.

[0134] Example 5:

[0135] Another embodiment of the present invention provides a piece of furniture, including a composite board 100. The composite board 100 is the composite board 100 described in any of the above embodiments. The composite board 100 includes a straw board 110 and a ceramic slab 120 attached to the surface of the straw board 110. The ceramic slab 120 can improve the aesthetics and strength of the board surface, making the surface style more diverse, meeting the aesthetic needs of different groups, and highlighting the luxury and high-end nature of the furniture. At the same time, because the ceramic slab 120 itself has high hardness and good wear resistance, it can effectively prevent scratches or cracks from appearing on the board surface, resulting in high stability of the board. Furthermore, since the composite board 100 uses the straw board 110 as a substrate, the straw board 110 can effectively improve the nail-holding power of the composite board 100. Furthermore, since the ratio of the water absorption thickness expansion rate of the straw board 110 and the ceramic rock board 120 is within the range of 0.05 to 20, it can prevent the composite board 100 from being damaged due to the delamination of the straw board 110 and the ceramic rock board 120 during long-term use.

[0136] Example 6:

[0137] Understandably, the substrate 110 is not limited to being made of strawboard. See also Figure 7 One embodiment of the present invention provides a composite board 200, including an aluminum foam board 210 and a ceramic rock board 220.

[0138] The foamed aluminum board 210 is made of foamed aluminum material. Foamed aluminum is produced by adding additives to pure aluminum or aluminum alloys and then performing a foaming process. Foamed aluminum combines the characteristics of both metal and porous materials, and has advantages such as low density, high impact absorption capacity, high temperature resistance, strong fire resistance, corrosion resistance, sound insulation and noise reduction, low thermal conductivity, high electromagnetic shielding, strong weather resistance, filtering ability, easy processing, easy installation, high forming precision, and the ability to be surface coated.

[0139] The ceramic rock slab 220 is attached to the first surface of the aluminum foam slab 210.

[0140] In the composite panel 200 provided in this embodiment, a ceramic slab 220 is attached to the surface of the aluminum foam board 210. The ceramic slab 220 can improve the aesthetics and strength of the board surface, making the surface style of the board more diverse, meeting the appearance needs of different groups of people, and highlighting the luxury and high-end nature of the furniture. On the other hand, since the ceramic slab 220 itself has high hardness and good wear resistance, attaching the ceramic slab 220 to the surface of the aluminum foam board 210 can effectively prevent scratches or cracks from appearing on the board surface, thereby making the composite panel more stable.

[0141] Furthermore, since the composite panel 200 uses aluminum foam board 210 as the substrate, and the aluminum foam board 210 has many irregularly sized pores, it effectively improves the nail-holding power of the aluminum foam board 210, making the composite panel 200 easy to splice and assemble with screws. On the other hand, since the difference in mechanical properties between the aluminum foam board 210 and the ceramic slab 220 is small, it can prevent the composite panel 200 from delaminating during long-term use, thus avoiding damage. In particular, during the cutting process of the composite panel 200, even if the ceramic slab 220 needs to be sprayed with water, the aluminum foam board 210 is not easily deformed after absorbing water, thus preventing the delamination of the aluminum foam board 210 and the ceramic slab 220 during the cutting process. In other words, in this embodiment, since the aluminum foam board 210 is made of metal, its size is not easily changed after absorbing water, thereby avoiding the phenomenon of the composite board being damaged due to the delamination of the aluminum foam board 210 and the ceramic rock board 220 during long-term use.

[0142] In fact, in the field of furniture panels, another important evaluation factor is the machinability of the panels. That is, a large panel needs to be cut into smaller panels of various shapes and lengths, and then these smaller panels are assembled together using methods such as gluing or screwing. However, due to the high hardness and density of ceramic slabs, water is usually needed for cooling during cutting. If the substrate of the composite panel is wood, the dimensional changes of wood after absorbing water are relatively large, while those of ceramic slabs are relatively small. This can easily cause the wood substrate and ceramic panel to delaminate during the cutting process, leading to damage to the composite panel. In the composite panel provided in this embodiment of the invention, the substrate is aluminum foam board 210. Because aluminum foam board 210 has relatively stable properties, its dimensions are less prone to change after absorbing water. Therefore, even when water cooling is used during the cutting process of the composite panel composed of aluminum foam board 210 and ceramic slab 220, the dimensions of the aluminum foam board 210 will not change significantly, thus preventing damage to the aluminum foam board 210 and ceramic slab 220 due to inconsistent water absorption and expansion rates. In other words, the composite panel made of aluminum foam board 210 and ceramic slab 220 has excellent resistance to mechanical cutting. Especially when the ceramic slab 220 requires water-cooled cutting, the mechanical cutting resistance of the composite panel composed of aluminum foam board 210 and ceramic slab 220 is even more outstanding.

[0143] In one embodiment, the density of the aluminum foam board 210 is set between 0.2 and 0.4 g / cm³. 3Within the specified range, the density of the aluminum foam board 210 is set between 0.2 and 0.4 g / cm³. 3 Within this range, it can be ensured that while having high nail-holding power, the overall weight of the composite board will not be excessive. For example, when the composite board composed of the foamed aluminum board 210 is used in a door panel, the resulting door panel is lighter and easier to open and close. In addition, since the foamed aluminum board 210 has good sound insulation and noise reduction properties, the resulting door panel also has good sound insulation performance.

[0144] In one embodiment, the composite panel 200 further includes a liner 230. The liner 230 is attached to a second surface 212 of the aluminum foam panel 210 opposite to the first surface 211. In this embodiment, the liner 230 comprises a second ceramic slab. By providing a ceramic slab 220 on the first surface 211 of the aluminum foam panel 210 and a liner 230 made of a second ceramic slab on the second surface 212 of the aluminum foam panel 210, the wear resistance of both sides of the composite panel 200 will be better, making the composite panel 200 more suitable for applications in the door panel field. In this embodiment, the thickness of the liner 230 is less than or equal to the thickness of the ceramic slab 220. By attaching a backing plate 230 to the second surface of the aluminum foam board 210 opposite to the first surface, the backing plate 230 effectively protects the aluminum foam board 210 from corrosion. Furthermore, since both surfaces of the aluminum foam board 210 are covered by the ceramic slab 220 and the backing plate 230 respectively, the waterproof performance of the composite board 200 is further improved. In this way, during use, the composite board 200 is less likely to delaminate and break due to the difference in water absorption and expansion rates between the ceramic slab 220 and the aluminum foam board 210.

[0145] In this embodiment, the water absorption thickness expansion rate of the aluminum foam board 210 is less than or equal to 0.1%. Because the water absorption thickness expansion rate of the aluminum foam board 210 is less than or equal to 0.1%, it can be fully adapted to the water absorption thickness expansion rate of the ceramic slab 220. If necessary, the water absorption thickness expansion rate of the composite board 200 is less than or equal to 0.05%. Besides the water absorption thickness expansion rate, the water absorption dimensional change rate in the length or width direction is also an important consideration for furniture boards. If necessary, the water absorption length change rate or water absorption width change rate of the aluminum foam board 210 is also less than or equal to 0.1%, thereby achieving the adaptation process with the ceramic slab 220.

[0146] Understandably, the porosity and pore size of the aluminum foam board 210 also affect the mechanical properties of the resulting composite board 200. In one embodiment, the aluminum foam board 210 has a closed-cell structure. The porosity of the aluminum foam board 210 is in the range of 80% to 90%. The pore size of the aluminum foam board 210 is in the range of 0.4 to 5 mm. By setting the aluminum foam board 210 to a closed-cell structure, the nail-holding force of the aluminum foam board 210 can be further improved, and the machinability of the aluminum foam board 210 can be enhanced. In addition, selecting an aluminum foam board 210 with a pore size in the range of 0.4 to 5 mm can also improve the nail-holding force of the aluminum foam board 210 due to the smaller pore size.

[0147] In one embodiment, the ratio of the coefficient of thermal expansion of the aluminum foam board 210 to that of the ceramic slab 220 is within the range of 0.2 to 5. Similarly, by setting the ratio of the coefficient of thermal expansion of the aluminum foam board 210 to that of the ceramic slab 220 to be within the range of 0.2 to 5, when the temperature difference in the environment where the composite board is used is large, the aluminum foam board 210 and the ceramic slab 220 will not delaminate and be damaged due to inconsistent dimensional changes.

[0148] The thickness of the aluminum foam board 210 is greater than or equal to 12 mm. In one embodiment, the thickness of the aluminum foam board 210 is in the range of 12 to 40 mm. The thickness of the ceramic slab 220 is greater than or equal to 1 mm. In one embodiment, the thickness of the ceramic slab 220 is in the range of 1 to 6 mm. The purpose of setting the thickness of the aluminum foam board 210 in the range of 12 to 40 mm is that, since the density of the aluminum foam board 210 is significantly less than that of the ceramic slab 220, a thickness of approximately 12 to 40 mm can significantly reduce the overall weight of the composite board 200; at the same time, setting the thickness of the aluminum foam board 210 in the range of 12 to 40 mm can also ensure that the resulting composite board 200 has high nail-holding power. In other words, when the thickness of the aluminum foam board 210 is in the range of 12 to 40 mm, the composite board 200 has high nail-holding power while the weight of the board is not excessive, making installation and transportation convenient and more comfortable to use. In general, nail-holding force refers to the performance of wood in securing metal fasteners (nails, wood screws, etc.), calculated as the force required to pull out a screw of a certain size. In this embodiment, the nail-holding force of the composite board composed of the foamed aluminum board 210 and the ceramic rock board 220 is greater than or equal to 10 N / mm². 2 It is evident that the composite board 200 provided in this embodiment of the invention has a high nail-holding force, which meets the needs of the furniture industry.

[0149] The purpose of setting the thickness of the ceramic slab 220 within the range of 1 to 6 mm is to allow it to adapt to the needs of different usage scenarios. When the composite board 200 is used on non-high load-bearing surfaces such as furniture side panels or door panels, a thinner ceramic slab 220 is sufficient. Conversely, when the composite board 200 is used on high load-bearing surfaces such as furniture countertops or cabinet panels, a thicker ceramic slab 220 is selected. In this embodiment, the thickness of the ceramic slab 220 is preferably 3 mm. At this thickness, the weight, wear resistance, and load-bearing capacity of the ceramic slab 220 are moderate, meeting the needs of most users. Furthermore, the production cost of the ceramic slab 220 is relatively low, making it a versatile option.

[0150] In one embodiment, the composite board 200 further includes a first adhesive layer 240 and a second adhesive layer 250.

[0151] The first adhesive layer 240 is disposed between the aluminum foam board 210 and the ceramic slab 220, for attaching the ceramic slab 220 to the aluminum foam board 210. The second adhesive layer 250 is disposed between the aluminum foam board 210 and the liner 230, for attaching the liner 230 to the aluminum foam board 210. In this embodiment, the liner 230 can be made of a metal plate or a second ceramic slab. When the liner 230 is made of a second ceramic slab, the material of the liner 230 can be the same as or different from the material of the ceramic slab 220. Furthermore, when the liner 230 is made of a second ceramic slab, the thickness of the liner 230 is less than the thickness of the ceramic slab 220. In this embodiment, the ceramic slab 220 is attached to the first surface of the aluminum foam board 210 via a first adhesive layer 240; the liner 230 is attached to the second surface of the aluminum foam board 210 via a second adhesive layer 250. Both the first adhesive layer 240 and the second adhesive layer 250 are reactive hot melt adhesive materials. It is understood that either the first adhesive layer 240 or the second adhesive layer 250 can also be set as a reactive hot melt adhesive material. In one embodiment, the reactive hot melt adhesive material is a reactive polyurethane (PUR) hot melt adhesive material. Since PUR hot melt adhesive materials do not contain organic solvents, they can be applied at lower temperatures. Initial bonding is achieved by cooling and solidification after adhesive application. In subsequent processes, the PUR hot melt adhesive material undergoes moisture curing in the air, and after complete curing, it exhibits excellent bonding strength and impact resistance. Therefore, by bonding the aluminum foam board 210, the ceramic rock board 220, and the lining board 230 together with the reactive hot melt adhesive material, the resulting composite board has high bonding strength.

[0152] Therefore, in this embodiment, the ceramic slab 2 and the liner 230 are respectively attached to the first surface 211 and the second surface 212 of the aluminum foam board 210 using reactive hot melt adhesive. The aluminum foam board 210, the ceramic slab 220, the liner 230, the first adhesive layer 240, and the second adhesive layer 250 are integrated into a composite board structure after being cured by heating and pressurizing.

[0153] In one embodiment, the reactive hot melt adhesive is a PUR reactive hot melt adhesive. When attaching the ceramic slab 220 and the backing plate 230 to the aluminum foam board 210, the PUR reactive hot melt adhesive is first placed in a hot melt machine. After preheating, heating, and dispensing, the PUR reactive hot melt adhesive is applied to the surface of the backing plate 230, forming a second adhesive layer 250 with a thickness of 0.1 to 0.2 mm. Then, the aluminum foam board 210 is placed face-up over the second adhesive layer 250, and a first adhesive layer 240 with a thickness of 0.1 to 0.2 mm is applied to the upper surface (first surface) of the aluminum foam board 210. The ceramic slab 220 is then placed face-up over the second adhesive layer 250 to form a pre-finished composite panel. The pre-finished composite panel is then placed in a hot press for heating and pressure curing to form the finished composite panel. During the manufacturing process, the PUR reactive hot melt adhesive is preheated at a temperature between 80 and 110°C, and heated at a temperature between 120 and 130°C. Excessive heating temperature can easily cause the PUR reactive hot melt adhesive to crack and carbonize, thus affecting its adhesive properties. In application, the composite board is cut to the required dimensions for furniture processing, and then edge-sealed to provide comprehensive protection. Therefore, the composite board provided in this embodiment of the invention has fireproof, waterproof, and insect-proof characteristics. Furthermore, to improve the adhesion between the aluminum foam board 210 and the ceramic slab 220, a wavy adhesive-laying groove can be formed on the first surface of the aluminum foam board 210. Simultaneously, to save on the amount of PUR reactive hot melt adhesive used, the wave height of the adhesive-laying groove is controlled within the range of 0.8 to 1.2 mm, and the wavelength is controlled within the range of 1.2 to 1.8 mm. The adhesive-laying groove is integrally formed with the aluminum foam board 210 during manufacturing. When PUR reactive hot melt adhesive is applied to the aluminum foam board 210 with this structure, the PUR reactive hot melt adhesive partially sinks into the adhesive-laying groove, resulting in better fusion with the PUR reactive hot melt adhesive and thus stronger adhesion between the aluminum foam board 210 and the ceramic slab 220. Furthermore, strict control of the wave height and wavelength of the adhesive-laying groove effectively avoids waste of PUR reactive hot melt adhesive, thereby controlling the production cost of the composite board provided in this embodiment of the invention. Simultaneously, the composite board of this invention passed formaldehyde content testing and showed no formaldehyde, classifying it as a zero-formaldehyde environmentally friendly board product.

[0154] Furthermore, in this embodiment, aluminum foam board 210 is used as the substrate of the composite board. The surface of the aluminum foam board 210 that is bonded to the ceramic rock slab 220 has a porous structure 213, such as... Figure 8 As shown. When the first adhesive layer 240 is used to bond the aluminum foam board 210 and the ceramic slab 220, the first adhesive layer 240 is partially disposed within the porous structure 213. That is, when the first adhesive layer 240 is used to bond the aluminum foam board 210 and the ceramic slab 220, the porous structure 213 on the surface of the aluminum foam board 210 can increase the contact area between the first adhesive layer 240 and the aluminum foam board 210, thereby improving the bonding performance between the aluminum foam board 210 and the ceramic slab 220.

[0155] Example 7:

[0156] Understandably, the surface of the aluminum foam board 210 can also be provided with an adhesive application groove 214, such as... Figure 9 As shown. The adhesive-laying groove 214 can improve the adhesion between the aluminum foam board 210 and the ceramic slab 220. Understandably, since the surface of the aluminum foam board 210 has a porous structure 213, the porous structure 213 is also located within the groove of the adhesive-laying groove 214, thereby further improving the adhesion between the aluminum foam board 210 and the ceramic slab 220.

[0157] Understandably, the sides of the aluminum foam board 210 and the ceramic rock board 220 are also provided with edge sealing strips (not shown). The edge sealing strips cover the sides of the aluminum foam board 210 and the ceramic rock board 220, thereby preventing moisture or other pollutants from entering the interior of the composite board 200.

[0158] Example 8:

[0159] Another embodiment of the present invention discloses a door panel made using the composite board provided in any of the above embodiments. Please see below. Figure 10 and Figure 11The door panel 300 provided in this embodiment of the invention includes a composite board 200, which is the composite board 200 provided in any of the above embodiments. In this embodiment, an edge banding strip 260 is also provided on the outer periphery of the door panel 300. When manufacturing the door panel 300, a composite board is generally used to cut the door panel 300 to a specified size according to the specifications of the door panel 300. After cutting the door panel 300, in order to protect the outer edge of the door panel 300 and to avoid cracking and deformation of the door edge, an edge banding treatment is performed on the outer periphery of the door panel 300. Specifically, in the door panel structure provided in this embodiment of the invention, the door panel 300 is protected by attaching an edge banding strip 260 to the outer periphery. Preferably, in order to further enhance the structural strength and appearance of the door panel structure, the edge banding strip 260 includes an outer surface layer 270 for serving as the outer surface of the edge banding strip 260. The outer surface layer 270 is made of aluminum sheet, aluminum alloy sheet or ABS plastic sheet. ABS plastic is a terpolymer of acrylonitrile (A), butadiene (B), and styrene (S). The relative contents of the three monomers can be varied to create various resins. ABS plastic possesses the common properties of all three components. Acrylonitrile (A) makes it resistant to chemical corrosion and heat, and provides a certain surface hardness; butadiene (B) gives it high elasticity and toughness; and styrene (S) gives it the processing and molding characteristics of thermoplastic plastics and improves its electrical properties. Due to the excellent properties of ABS plastic sheets, they can be used as the outer surface layer 270 of the edge banding strip 260. Preferably, because the material cost of aluminum sheets or aluminum alloy sheets is relatively high, in order to strictly control the cost of the edge banding strip 260, the edge banding strip 260 can be manufactured as a composite layer of aluminum sheet and PVC adhesive layer 280 or aluminum alloy sheet and PVC adhesive layer 280. The thickness of the aluminum sheet or aluminum alloy sheet is 0.03 mm. The outer surface layer 270 is provided with a PVC adhesive layer 280 on the side that adheres to the outer periphery of the door panel 300. The thickness of the edge banding strip 260 is 1 mm. The composite layer of aluminum sheet and PVC adhesive layer 280, or the composite layer of aluminum alloy sheet and PVC adhesive layer 280, allows the edge banding strip 260 to have the appearance and texture of an aluminum sheet or aluminum alloy sheet on its outer surface. Simultaneously, the PVC adhesive layer 280 on its inner side allows the aluminum sheet or aluminum alloy sheet to fully unfold for easy attachment, thus giving the edge banding strip 260 the corresponding structural strength. Therefore, forming a 1mm thick edge banding strip 260 by combining a 0.03mm thick aluminum sheet or aluminum alloy sheet with a PVC adhesive layer 280 significantly reduces material costs compared to directly using a 1mm thick aluminum sheet or aluminum alloy sheet, while also providing better toughness and a superior sealing effect. In this embodiment, the edge banding strip 260 is attached to the outer periphery of the door panel 300 via a third adhesive layer 290. Alternatively, the edge banding strip 260 can also be formed by laminating ABS plastic sheet with a PVC adhesive layer 280.

[0160] The above description is merely a preferred embodiment of the present invention and does not limit the patent scope of the present invention. Any equivalent structural transformations made using the contents of the present invention's specification and drawings under the inventive concept of the present invention, or direct / indirect applications in other related technical fields, are included within the patent protection scope of the present invention.

Claims

1. A composite board, characterized by, Comprise: a substrate having a first surface and a second surface, the substrate being a straw board, the straw board having a water absorption thickness expansion rate of less than or equal to 0.6%, the straw board having a density in the range of 0.4 to 0.8 g / cm 3 and a first ceramic rock plate attached to a first surface of the substrate; wherein a ratio of a water absorption thickness expansion rate of the substrate to a water absorption thickness expansion rate of the first ceramic rock plate is within a range of 0.05 to 20; The composite board has a nail holding force of greater than or equal to 10 N / mm 2 .

2. The composite sheet of claim 1, wherein the fire resistance performance of the composite board comprises: a burning growth rate of the composite board is less than or equal to 250 W / s; and / or, a lateral flame spread of the composite board is less than or equal to an edge of the composite board; and / or, a total heat release of the composite board within the first 600 seconds of exposure to a burner flame is less than or equal to 15 MJ.

3. The composite sheet of claim 1, wherein The composite board has a formaldehyde release amount of less than or equal to 0.06 mg / m 3 .

4. The composite sheet of claim 1, wherein a water absorption thickness expansion rate of the composite board is less than or equal to 0.1%; and / or, a water absorption length change rate of the straw board is less than or equal to 0.4%; and / or, a water absorption width change rate of the straw board is less than or equal to 0.4%.

5. The composite sheet of claim 1, wherein a ratio of a water absorption rate of the straw board to a water absorption rate of the ceramic rock plate is within a range of 0.05 to 20.

6. The composite board of claim 1, wherein: a thickness of the first ceramic rock plate is within a range of 3 to 6 mm.

7. Furniture comprising a composite panel, characterized in that the composite board is the composite board of any one of claims 1 to 6.

8. A door panel comprising a composite panel, characterized in that the composite board is the composite board of any one of claims 1 to 6.

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