Building board

Abstract

The invention relates to a building board which sequentially comprises the following layered structures: a transparent protective layer, a decorative layer, a flame-retardant layer, a thermoplastic core layer and at least one reinforcing layer. The thermoplastic core layer is made of a composite material containing thermoplastic polyvinyl chloride and an inorganic filler, and the content of the inorganic filler is 20-60% of the total weight of the core layer. The reinforcing layer is arranged on the other side, opposite to the flame-retardant layer, of the thermoplastic core layer. The reinforcing layer is used for improving the nail-holding power of the building board, the building board is subjected to special-shaped plastic processing through a thermal forming process, and through the synergistic effect of a PVC-mineral composite system and a multi-layer structural design, the board has excellent structural stability, excellent construction convenience and wide environmental adaptability; and the economic cost performance is higher.

Description

Technical Field

[0001] This invention belongs to the field of panel technology, specifically a building panel. Background Technology

[0002] Currently, conventional structural panels widely used in wall, ceiling, and floor systems, such as oriented strand board (OSB), particleboard, gypsum board, magnesium oxide board, fiber cement board, and plywood, generally suffer from numerous technical defects, such as insufficient moisture resistance, inadequate fire resistance, and various structural flaws. These defects severely limit their practicality, versatility, and durability in residential and commercial buildings. The most prominent technical defect lies in their limited load-bearing capacity. Materials such as gypsum board, OSB, particleboard, magnesium oxide board, and fiber cement board typically exhibit low tensile, compressive, and flexural strengths, making them unsuitable for applications requiring structural support, such as floor subfloors or dynamically load-bearing wall components. Insufficient moisture resistance manifests as easy expansion and deformation when exposed to moisture, structural disintegration, and the growth of fungi and microorganisms. Magnesium oxide boards also exhibit efflorescence and dimensional instability. Fiber cement boards are prone to cracking and warping in prolonged humid environments, and freeze-thaw cycles accelerate material degradation. The aforementioned moisture-proof defects severely affect the durability and structural safety of the panels in damp spaces such as bathrooms, kitchens, and basements, as well as in exterior facade applications.

[0003] In terms of fire resistance, existing building materials also pose serious safety hazards. For flammable materials such as oriented strand board (OSB), particleboard, and plywood, the presence of combustible materials promotes rapid flame spread and produces toxic fumes during combustion, significantly increasing the fire risk. While gypsum board itself does not burn, its fire resistance is only temporary, and its structure collapses rapidly upon contact with water. Although some fire-retardant materials, such as magnesium oxide boards and fiber cement boards, are non-combustible, their brittleness and high thermal conductivity make them prone to structural collapse under prolonged fire conditions.

[0004] The aforementioned boards also suffer from an inherent defect of low elastic modulus. Their weak mechanical properties are mainly due to factors such as structural defects caused by insufficient internal cohesion, manufacturing defects caused by high porosity, and poor adhesion between material phases. As is well known, a low elastic modulus leads to poor performance under elastic deformation conditions; it is difficult to adapt to flexible or dynamic structural environments, and it cannot return to its original shape after mechanical strain.

[0005] Existing boards also have significant defects in impact resistance. Materials such as gypsum board, magnesium oxide board, oriented strand board (OSB) and fiber cement board are inherently brittle. In addition, they lack internal reinforcement structures and energy dissipation mechanisms, making them extremely susceptible to the following forms of damage when subjected to impact, such as edge chipping, surface cracking, interlayer delamination, and overall fracture.

[0006] In addition to the structural and performance defects mentioned above, existing types of boards also have their own inherent defects. For example, gypsum board is prone to mold growth and is a non-load-bearing structure, making it fragile and easily damaged. Fiber cement board has a large self-weight, rough surface, and is difficult to process due to the presence of crystalline silica. Summary of the Invention

[0007] In view of this, the present invention provides an interior building panel suitable for wall, floor or ceiling assembly to solve the above-mentioned technical problems.

[0008] A building panel comprises, in sequence, the following layered structure: a transparent protective layer, a decorative layer, a flame-retardant layer, a thermoplastic core layer, and at least one reinforcing layer. The thermoplastic core layer is made of a composite material comprising thermoplastic polyvinyl chloride and inorganic fillers, wherein the content of the inorganic fillers is 20% to 60% of the total weight of the core layer. The reinforcing layer is disposed on the opposite side of the thermoplastic core layer relative to the flame-retardant layer. The reinforcing layer is used to improve the nail-holding power of the building panel, and the building panel is shaped and plastically processed by a thermoforming process.

[0009] Furthermore, the thermoplastic core layer has a density gradient in the thickness direction, with the density of the two surface regions near the flame-retardant layer and the reinforcing layer being higher than the density of the middle core region of the thermoplastic core layer.

[0010] Furthermore, the reinforcing layer is made of glass fiber, jute, or cotton.

[0011] Furthermore, the flame-retardant layer is one or more of the following: aluminum foil layer, carbon fiber felt, carbon-reinforced polymer film, and polymer foam layer.

[0012] Furthermore, the raw materials for manufacturing the flame-retardant layer also include flame-retardant additives, which include one or more of aluminum hydroxide, magnesium hydroxide, zinc borate, and expanded graphite.

[0013] Furthermore, at least one side edge of the building panel is provided with a sealing layer.

[0014] Furthermore, at least one edge of the building panel is provided with a connecting structure for connecting with adjacent building panels.

[0015] Furthermore, the density of the thermoplastic core layer is between 900 and 1200 kg / m³, and / or the flexural modulus is between 8000 and 12000 MPa.

[0016] Furthermore, the Vicat softening temperature of the thermoplastic polyvinyl chloride is between 70°C and 90°C.

[0017] Compared with existing technologies, the building panel provided by this invention, through the synergistic effect of a PVC-mineral composite system and a multi-layer structural design, exhibits superior structural stability, excellent ease of construction, wide environmental adaptability, and higher cost-effectiveness. Specifically, to address the issue of limited load-bearing capacity, this panel employs a core layer composed of a special engineering mixture of high-rigidity PVC, high-molecular-weight PVC, and cross-linked PVC, reinforced with mineral-based fillers. This significantly improves the tensile, compressive, and flexural strength of the panel, enabling it to withstand static and dynamic loads. Simultaneously, the addition of cross-linked PVC contributes to long-term structural stability and resistance to deformation. To solve the prevalent moisture-proofing problem in existing technologies, this panel adopts a multi-protection design: the core layer uses a PVC-mineral filler composite system, whose inherent moisture-proof properties significantly reduce the risk of expansion, delamination, and mold; the inner surface is treated with an anti-permeability coating, forming a moisture barrier; this design ensures that the panel maintains dimensional stability and structural integrity in high-humidity environments such as kitchens and bathrooms, as well as in exterior wall applications.

[0018] To address the fire resistance deficiencies of existing flammable or thermally unstable materials, this board employs a multi-level fire protection system. The board integrates an aluminum foil layer as a thermal insulation barrier, significantly improving high-temperature resistance and slowing heat conduction. Both the core and intermediate layers are coated with flame-retardant coatings, effectively inhibiting flame spread and structural collapse. In particular, flame retardants are added to the PVC composite core material, reducing both flammability and the generation of toxic fumes, thus greatly enhancing the safety of occupants during a fire.

[0019] To address the issue of low elastic modulus in traditional sheet materials, this sheet material achieves a breakthrough by strengthening the internal bonding mechanism. Specifically, the core layer and intermediate layer utilize chemical bonding agents and surface treatment processes to significantly improve the interfacial adhesion strength of the component materials, thereby enhancing mechanical cohesion and flexibility. The design employs an isotropic structural configuration and optimized curing process to synergistically reduce internal porosity and manufacturing defects. Furthermore, reinforcing layers such as glass fiber or carbon fiber can be implanted to significantly improve the elastic modulus, ultimately resulting in a sheet material that combines high rigidity and flexibility, perfectly suited for dynamic structural applications.

[0020] This board also employs a gradient multi-layer structure design to address the issue of insufficient impact resistance. The low-crystallinity PVC composite core layer effectively absorbs and dissipates impact energy, reducing the risk of breakage, while the surface layer uses highly crystalline PVC areas rich in high-hardness mineral fillers such as calcium carbonate, silica fume, and wollastonite, forming a shatter-resistant protective shell. Through the gradient distribution of filler concentration, the board possesses both excellent impact resistance and maintains structural integrity and functionality even after high-stress impacts.

[0021] From a health and safety perspective, this invention completely eliminates harmful substances such as crystalline silica and asbestos, making the boards safer during processing and installation—a significant advantage compared to the risk of harmful dust generated during the cutting and installation of fiber cement boards (CFC boards). Through the systematic integration of edge sealing treatment, a moisture-proof core layer, and a flame-retardant layer, the durability and service life of the boards of this invention are significantly improved compared to traditional gypsum board, oriented strand board (OSB), and particleboard.

[0022] This board also boasts excellent decorative adaptability and versatility. Its specially treated surface perfectly complements decorative materials such as paint, wallpaper, and laminated finishes, achieving seamless integration with various interior design styles. Combining fire resistance, moisture resistance, load-bearing capacity, ease of installation, and decorative properties, this invention's board has become a superior alternative to traditional building materials in residential, commercial, and industrial construction.

[0023] Through the systematic integration of the above-mentioned innovative technologies, this invention not only addresses the common performance defects of existing structural panels, but also fundamentally breaks through their durability limitations, providing a comprehensive and optimized integrated solution. Attached Figure Description

[0024] Figure 1 This is a structural schematic diagram of a building panel provided by the present invention.

[0025] Figure 2 This is a structural schematic diagram of another building material provided by the present invention. Detailed Implementation

[0026] The following provides a more detailed description of specific embodiments of the present invention. It should be understood that the description of the embodiments of the present invention herein is not intended to limit the scope of protection of the present invention.

[0027] like Figure 1The diagram shown is a structural schematic of a building panel provided by the present invention. The building panel includes at least one thermoplastic core layer 10, at least one reinforcing layer 20 disposed on one side of the core layer 10, a flame-retardant layer 30 disposed on the other side of the core layer 10, a decorative layer 40 disposed on one side of the flame-retardant layer 30, and a transparent protective layer 50 disposed on one side of the decorative layer 40. It is conceivable that the interior building panel may also include other functional structures, such as adhesive layers disposed between the functional layers, and paint layers disposed on the transparent protective layer, etc., which are techniques well known to those skilled in the art and will not be described in detail here.

[0028] The core layer 10 comprises at least one layer, and may also comprise two or more layers. When there are two or more layers, the multiple core layers 10 can be overlapped and glued together. When the core layer 10 has multiple layers, each core layer 10 can be made of the same material or different materials. Each core layer 10 is formed by extrusion molding, and in particular, can be shaped and plastically processed by thermoforming processes, i.e., custom processing. The raw material for manufacturing the core layer 10 is a composite material of thermoplastic polyvinyl chloride and inorganic fillers. The content of the inorganic filler is 20% to 60% of the total weight of the core layer. The thermoplastic polyvinyl chloride can be a mixture of high molecular weight PVC and modified PVC, with a Vicat softening temperature between 70°C and 90°C.

[0029] The K-value of the high molecular weight PVC is preferably between 67 and 80. This high molecular weight PVC can enhance mechanical strength, improve thermal stability, and increase creep resistance under long-term load. Compared to conventional low molecular weight PVC formulations, the high molecular weight PVC significantly improves elastic modulus, toughness, and dimensional stability by increasing molecular chain entanglement and intermolecular forces in the polymer matrix. The high molecular weight PVC is composed of high-crystallinity PVC and low-crystallinity PVC. The content of high-crystallinity PVC accounts for 40% to 60% of the high molecular weight PVC, with the remainder being low-crystallinity PVC. During extrusion molding, a multi-layer extrusion process should be used, and the composite material containing high-crystallinity PVC should be coated on the outside of the composite material containing low-crystallinity PVC. This creates a multi-layer structure with a density gradient; that is, in the thickness direction of the core layer 10, the density of the two surface regions near the flame-retardant layer 30 and the reinforcing layer 20 is higher than the density of the central core region of the core layer 10, thus helping to solve the problem of insufficient impact resistance. This is because the low-crystallinity PVC composite core layer can effectively absorb and dissipate impact energy, reducing the risk of fracture. The surface layer uses highly crystalline PVC, combined with high-hardness mineral fillers from inorganic materials, to form a shatter-resistant protective shell. Through this density gradient distribution, the board not only possesses excellent impact resistance but also maintains structural integrity and functionality after high-stress impacts.

[0030] The modified PVC is achieved through chemical modification, which involves modifying the PVC using peroxide-based crosslinking agents or co-agents. The PVC can be any PVC material. The peroxide-based crosslinking agent or co-agent can be triallyl isocyanurate or trimethylolpropane trimethacrylate, or a mixture thereof. During the extrusion and curing process of the composite material used to form the core layer 10, the peroxide-based crosslinking agent or co-agent can promote the formation of a three-dimensional polymer network composed of covalent bonds between the PVC polymer chains, thereby significantly improving the thermal stability, creep resistance, and mechanical rigidity of the PVC matrix.

[0031] The inorganic filler can be magnesium oxide, magnesium carbonate, magnesium oxysulfate, magnesium oxychloride cement (MOC), magnesium chloride, magnesium sulfate, Sorel cement, fiber cement, MOS cement, limestone, calcium carbonate, calcite minerals, stone, chalk, clay, calcium silicate, aluminum hydroxide, magnesium hydroxide, and / or talc powder and combinations thereof. Using calcium carbonate, silica, and kaolin can improve the strength of the manufactured slabs and also help improve their thermal stability.

[0032] The core layer 10 is formed by extrusion molding, and its density is 900–1200 kg / m³. Selecting this density range achieves an optimal balance between mechanical strength and ease of installation. The density of the core layer 10 is mainly controlled by adjusting the ratio of polyvinyl chloride to inorganic fillers.

[0033] The core layer 10 has a flexural modulus of 8,000–12,000 MPa. This flexural performance makes the board significantly superior to traditional gypsum board, oriented strand board (OSB), and magnesium oxide board. By maintaining a high flexural modulus within a density range of 900–1200 kg / m³, the core layer 10 ensures excellent mechanical properties, ease of construction, and does not increase the structural dead load.

[0034] Through the selection of the aforementioned materials, the core layer 10 exhibits low thermal expansion characteristics, with a linear coefficient of thermal expansion (CLTE) ranging from 0.15 to 0.25 mm / m·°C. This characteristic ensures that the core layer 10 maintains dimensional stability even when faced with indoor temperature fluctuations such as HVAC operation and solar radiation heat, which create temperature gradients within the wall or ceiling components. Specifically, this low thermal expansion performance is achieved by employing inorganic mineral reinforcing materials such as calcium carbonate, which, combined with rigid polyvinyl chloride matrix, restrict the movement of polymer chains, thereby effectively suppressing thermal expansion of the material.

[0035] Through the selection of the aforementioned materials, the water absorption rate of the core layer 10 is less than 0.5%, meaning that the water absorbed by the core layer 10 accounts for 0.5% of its total weight. This data was determined using a standard immersion test method such as ASTM D570. This excellent low water absorption characteristic is mainly due to the use of a hydrophobic polymer matrix, namely polyvinyl chloride (PVC), and non-hygroscopic inorganic mineral fillers. The inherent waterproof properties of PVC, combined with the dense microstructure formed during the extrusion of the composite material, effectively prevent moisture penetration into the core layer 10, maintaining stable performance even under long-term exposure to high humidity environments or intermittent water contact conditions. Due to the low water absorption rate, boards with this core layer 10 can be installed in damp or moisture-prone areas such as bathrooms, kitchens, basements, or laundry rooms. It is well known that traditional boards such as gypsum board and particleboard are prone to swelling, warping, mold growth, and structural degradation in these areas. In addition, by keeping the water absorption rate below 0.5%, the board also has excellent dimensional stability, mildew resistance and durability, ensuring a long service life and stable performance in both structural and unstructured indoor applications.

[0036] The reinforcing layer 20 can be one layer or two layers. When there are two reinforcing layers 20, the two layers 20 are bonded together. The reinforcing layer 20 can be a mesh structure layer made of glass fiber, jute, and / or cotton. When the core layer 10 is extruded, the reinforcing layer 20 can be directly laid on the surface of the core layer 10 and then rolled. It is conceivable that when two reinforcing layers 20 are provided, one layer of reinforcing layer 20 should be laid on the machine beforehand, the extruded core layer 10 should be laid directly on this reinforcing layer 20, and then another layer of reinforcing layer 20 should be laid on the core layer 10, followed by rolling. By providing the reinforcing layer 20, the strength of the core layer 10 can be further improved.

[0037] The flame-retardant layer 30 can be one or more of the following: an aluminum foil layer, carbon fiber felt or carbon-reinforced polymer film, and a polymer foam layer. The aluminum foil layer acts as a heat shield, reflecting radiant heat away from the structural core material, thereby further improving fire resistance, while also blocking moisture and vapor penetration. The carbon fiber felt or carbon-reinforced polymer film can increase the overall strength of the board, thereby improving its elastic modulus and crack resistance. The foam layer can be a polymer foam material formed from cross-linked polyethylene (XLPE), PVC, or polyurethane foam. The foam layer provides shock absorption and sound insulation, achieving a balance between structural performance and thermal and sound insulation effects. It is conceivable that the flame-retardant layer 30 can be a combination of the above three layers, thus achieving a combination of multiple functions. The flame-retardant layer 30 can be bonded to the surface of the core layer 10 using adhesives such as polyurethane, acrylic, epoxy resin, or hot melt adhesive. The flame-retardant layer 30 enables the board to meet higher performance requirements in load-bearing, heat insulation, and safety-critical applications.

[0038] The flame-retardant layer 30 can also be made of flame-retardant additives. These additives can be one or more of aluminum hydroxide, magnesium hydroxide, zinc borate, and expanded graphite. When using aluminum hydroxide, zinc borate can be added together. Aluminum hydroxide absorbs heat and decomposes at high temperatures, releasing water vapor, thereby cooling the material surface and diluting flammable gases. Simultaneously, when zinc borate is added, it works synergistically with aluminum hydroxide to promote the formation of a protective char layer, further achieving a flame-retardant effect. The expanded graphite expands at high temperatures, forming a carbonaceous insulating layer that blocks the transfer of heat and oxygen, further enhancing the flame-retardant effect. By using the flame-retardant additives and expanded graphite, the fire resistance of the core layer meets the Class A fire rating of ASTM E84 or an equivalent fire resistance standard. This high level of fire resistance is achieved by using a polyvinyl chloride (PVC) matrix, which has inherent flame retardancy due to its chlorine content. It is combined with flame-retardant mineral fillers such as aluminum hydroxide (ATH) and zinc borate, and expandable graphite is added, which releases water vapor or forms an insulating char layer barrier at high temperatures, thereby reducing flammability, slowing heat transfer, inhibiting flame spread and reducing smoke production.

[0039] The decorative layer 40 is disposed on the outer side of the board and may be a lignocellulose layer impregnated with a thermosetting composition. The thermosetting composition may be a melamine or polyurethane-based composition. The decorative layer 40 may also be a surface layer, such as wood veneer. The decorative layer 40 may also be at least one cellulose-based thin layer, preferably multiple cellulose-based thin layers. The cellulose-based thin layer may be paper, particularly kraft paper, including decorative paper, base paper, at least partially impregnated paper, covering layer, or any combination thereof. If a surface layer is used, it is preferably selected from the group consisting of wood veneer, cork veneer, bamboo veneer, etc. Other feasible materials include rubber veneer, decorative plastics or vinyl, linoleum flooring, and laminated decorative thermoplastic materials in the form of foil or film. If at least one thermoplastic material is used as the surface layer, the thermoplastic material may be polypropylene (PP), polyethylene terephthalate (PET), polyvinyl chloride (PVC), etc.

[0040] The decorative layer 40 may also consist of at least one decorative layer and / or at least one finishing layer. The finishing layer may be an ultraviolet-cured coating, an electron beam-modified resin, an excimer-cured coating, and / or an acrylic / polyurethane coating. The decorative layer may be attached to part or all of the surface of the core layer 10, and may also be a printed layer. Furthermore, decorative patterns on the decorative layer may also be formed by embossing on the surface of the core layer 10. Additionally, it is understood that a primer may be applied before applying the decorative printing.

[0041] When the decorative layer 40 is made of a thermoplastic material, one or more of the following materials may be added: silicon dioxide, aluminum oxide, graphene, silicone rubber, titanium dioxide, zinc oxide, zinc sulfide, corundum, silicon carbide, quartz, and / or silica. These materials are preferably added to the top layer 40 in particulate form. By adding these materials, the top layer 40 can improve its abrasion resistance, scratch resistance, and wear resistance.

[0042] The decorative layer 40 may also contain antimicrobial, antiviral, antibacterial, and / or antifungal agents. By adding antimicrobial, antiviral, antibacterial, and / or antifungal agents, microorganisms can be inhibited or killed, thereby protecting the surface layer.

[0043] The decorative layer 40 may also contain one or more anti-slip additives.

[0044] The transparent protective layer 50 is disposed on the free side of the decorative layer 40 and is used to protect the decorative layer 40. It can be a paint layer or a transparent resin layer, which is existing technology and will not be described in detail here.

[0045] like Figure 2As shown, the building panel further includes a connecting structure 60 disposed on at least one side thereof. This connecting structure is optional. The connecting structure 60 is disposed on at least a pair of opposite sides of the core layer 10 and is a complementary connecting structure. In a preferred embodiment, each pair of opposite sides of the building panel is provided with a complementary connecting structure. The connecting structure 60 is used for the mutual connection of adjacent panels, and is preferably an interlocking structure that can achieve interlocking in multiple directions, more preferably capable of horizontal and vertical bidirectional locking. The connecting structure 60 can adopt any applicable interlocking structure known in the art, such as complementary tongue and mortise structures, protrusions and fitting grooves, or other fitting forms. The connection method of the connecting structure 60 can be a downward scissor-like engagement or locking achieved by horizontal movement.

[0046] In addition, at least one side edge of the building panel is provided with a sealing layer, which helps to prevent moisture from penetrating the building panel from that side.

[0047] The building panel may further include a backing layer. The backing layer is disposed on the outer side of the reinforcing layer 20 relative to the core layer 10, and is fixed to the bottom surface of the reinforcing layer 20 by an adhesive. The backing layer is preferably made of a polymer material such as polyurethane, and can also serve as a sound-absorbing layer to enhance the acoustic performance of the panel. The backing layer may also be made of foamed material, preferably low-density foamed ethylene-vinyl acetate, radiation-crosslinked polyethylene, foamed polypropylene, and / or foamed polystyrene. Furthermore, the backing layer may also be made of natural fiber nonwoven materials such as hemp or cork, and / or recyclable materials such as PET. The density of the backing layer 500 is preferably 65-300 kg / m³, most preferably 80-150 kg / m³. Specific Implementation

[0048] The core layer materials are: 20% low-crystallinity high-molecular-weight PVC, 17% modified PVC, 15% a mixture of magnesium oxide, magnesium sulfate, fiber cement, limestone, and calcium carbonate, and 4% flame retardant additives; or 15% high-crystallinity high-molecular-weight PVC, 15% modified PVC, 10% a mixture of magnesium oxide, magnesium sulfate, fiber cement, limestone, and calcium carbonate, and 4% flame retardant additives. The core layer is extruded using a single machine with a double die.

[0049] Reinforcing layer: fiberglass mesh; Intermediate layer: aluminum foil layer, carbon fiber felt or carbon-reinforced polymer film, foam layer; Top layer: UV-cured decorative coating. The decorative layer is a printed layer; Backing layer: Foam material layer.

[0050] Comparative examples include: gypsum board, particleboard, magnesium oxide board, and fiber cement board. The experimental parameters above show that the bending strength of this board is significantly greater than that of existing boards, indicating greater hardness and less susceptibility to deformation. While its elastic modulus is similar to that of fiber cement board, it is superior to other types of boards, meaning this board is easy to bend and will not break. This makes it suitable for a wider range of applications, such as curved walls. Furthermore, this board exhibits optimal impact resistance, meaning it will not dent or break when subjected to heavy impacts. In conclusion, the above parameters demonstrate that this board surpasses most parameters of existing boards.

[0051] Compared with existing technologies, the present invention provides an indoor building panel suitable for wall, floor, or ceiling assembly. Through the synergistic effect of a PVC-mineral composite system and a multi-layer structural design, the panel exhibits superior structural stability, excellent ease of construction, wide environmental adaptability, and higher cost-effectiveness. Specifically, to address the issue of limited load-bearing capacity, this panel employs a core layer composed of a special engineering mixture of high-rigidity PVC, high-molecular-weight PVC, and cross-linked PVC, reinforced with mineral-based fillers. This significantly improves the tensile, compressive, and flexural strength of the panel, enabling it to withstand static and dynamic loads. Simultaneously, the addition of cross-linked PVC contributes to long-term structural stability and resistance to deformation. To solve the moisture-proof problem commonly found in existing technologies, this panel adopts a multi-protection design: the core layer uses a PVC-mineral filler composite system, whose inherent moisture-proof properties significantly reduce the risk of expansion, delamination, and mold; the inner surface is treated with an anti-permeability coating, forming a moisture barrier; this design ensures that the panel maintains dimensional stability and structural integrity in high-humidity environments such as kitchens and bathrooms, as well as in exterior wall applications.

[0052] To address the fire resistance deficiencies of existing flammable or thermally unstable materials, this board employs a multi-level fire protection system. The board integrates an aluminum foil layer as a thermal insulation barrier, significantly improving high-temperature resistance and slowing heat conduction. Both the core and intermediate layers are coated with flame-retardant coatings, effectively inhibiting flame spread and structural collapse. In particular, flame retardants are added to the PVC composite core material, reducing both flammability and the generation of toxic fumes, thus greatly enhancing the safety of occupants during a fire.

[0053] To address the issue of low elastic modulus in traditional sheet materials, this sheet material achieves a breakthrough by strengthening the internal bonding mechanism. Specifically, the core layer and intermediate layer utilize chemical bonding agents and surface treatment processes to significantly improve the interfacial adhesion strength of the component materials, thereby enhancing mechanical cohesion and flexibility. The design employs an isotropic structural configuration and optimized curing process to synergistically reduce internal porosity and manufacturing defects. Furthermore, reinforcing layers such as glass fiber or carbon fiber can be implanted to significantly improve the elastic modulus, ultimately resulting in a sheet material that combines high rigidity and flexibility, perfectly suited for dynamic structural applications.

[0054] This board also employs a gradient multi-layer structure design to address the issue of insufficient impact resistance. The low-crystallinity PVC composite core layer effectively absorbs and dissipates impact energy, reducing the risk of breakage, while the surface layer uses highly crystalline PVC areas rich in high-hardness mineral fillers such as calcium carbonate, silica fume, and wollastonite, forming a shatter-resistant protective shell. Through the gradient distribution of filler concentration, the board possesses both excellent impact resistance and maintains structural integrity and functionality even after high-stress impacts.

[0055] From a health and safety perspective, this invention completely eliminates harmful substances such as crystalline silica and asbestos, making the boards safer during processing and installation—a significant advantage compared to the risk of harmful dust generated during the cutting and installation of fiber cement boards (CFC boards). Through the systematic integration of edge sealing treatment, a moisture-proof core layer, and a flame-retardant layer, the durability and service life of the boards of this invention are significantly improved compared to traditional gypsum board, oriented strand board (OSB), and particleboard.

[0056] This board also boasts excellent decorative adaptability and versatility. Its specially treated surface perfectly complements decorative materials such as paint, wallpaper, and laminated finishes, achieving seamless integration with various interior design styles. Combining fire resistance, moisture resistance, load-bearing capacity, ease of installation, and decorative properties, this invention's board has become a superior alternative to traditional building materials in residential, commercial, and industrial construction.

[0057] Through the systematic integration of the above-mentioned innovative technologies, this invention not only addresses the common performance defects of existing structural panels, but also fundamentally breaks through their durability limitations, providing a comprehensive and optimized integrated solution.

[0058] The above are merely preferred embodiments of the present invention and are not intended to limit the scope of protection of the present invention. Any modifications, equivalent substitutions or improvements within the spirit of the present invention are covered within the scope of the claims of the present invention.

Claims

1. A building panel, characterised in that: The building board comprises a layered structure in the order of a transparent protective layer, a decorative layer, a fire-retardant layer, a thermoplastic core layer made of a composite material comprising thermoplastic polyvinyl chloride and inorganic filler, and at least one reinforcing layer, wherein the content of the inorganic filler is 20% to 60% of the total weight of the core layer, the reinforcing layer is arranged on the other side of the thermoplastic core layer relative to the fire-retardant layer, the reinforcing layer is used to improve the nail holding force of the building board, and the building board is subjected to special plastic processing through a thermoforming process.

2. The building panel of claim 1, wherein: The thermoplastic core layer has a density gradient in the thickness direction, and the density of the two surface layer regions close to the fire-retardant layer and the reinforcing layer is higher than the density of the middle core region of the thermoplastic core layer.

3. The building panel of claim 1, wherein: The reinforcing layer is made of glass fiber, jute or cotton.

4. The building panel of claim 1, wherein: The fire-retardant layer is one or several of an aluminum foil layer, a carbon fiber felt, a carbon-reinforced polymer film, and a polymer foaming layer.

5. The building panel of claim 1, wherein: The fire-retardant manufacturing raw material further comprises a fire-retardant additive, and the fire-retardant additive comprises one or several of aluminum hydroxide, magnesium hydroxide, zinc borate, and expanded graphite.

6. The building panel of claim 1, wherein: At least one side edge of the building board is provided with a sealing layer.

7. The building panel of claim 1, wherein: At least one edge of the building board is provided with a connecting structure for mutual connection with adjacent building boards.

8. The building panel of claim 1, wherein: The density of the thermoplastic core layer is between 900 and 1200 kg / m3, and / or the flexural modulus is between 8000 and 12000 MPa.

9. The building panel of claim 1, wherein: The Vicat softening temperature of the thermoplastic polyvinyl chloride is between 70°C and 90°C.

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