Plate facilitating improvement of assembly performance

Abstract

The invention relates to a plate favorable for improving assembly performance, which comprises at least one core layer and at least one mechanical lock catch structure arranged on the side wall of the core layer. The core layer is mainly prepared from a base material, a polymer adhesive, a bio-based fungus material and a fungus inducer, and the surface of the core layer is coated with a fungus blocking agent. At least part of the core layer of the plate is a bioactive locking interface composed of a completely renewable bio-based fungal material. According to the lock catch interface, an active interface is embedded in the side edge of the core layer, and adjacent plates are coupled through bio-oriented growth. Compared with a traditional interlocking system depending on a rigid synthetic component or an engineering machinery profile, the bioactive locking interface utilizes biological behaviors of active mycelia to achieve structural coupling and function enhancement at the same time.

Description

Technical Field

[0001] This invention belongs to the field of sheet metal technology, and in particular to a sheet metal that is beneficial to improving assembly performance. Background Technology

[0002] Traditional flooring and decorative building materials widely employ mechanical locking structures, such as tongue and groove joints, click-locking mechanisms, and snap-fit ​​structures. These mechanical locking structures are typically manufactured using synthetic or engineered materials as the primary base material, such as high-density fiberboard (HDF), medium-density fiberboard (MDF), laminated composites, and thermoplastics. Furthermore, to achieve the required precision for these mechanical locking connections, CNC grooving, milling, and surface finishing processes are often involved. These processes inevitably generate significant amounts of scrap, dust, and unusable waste. The processing waste from these mechanical locking structures is often composed of non-biodegradable resin-based composite materials, making efficient recycling impossible and directly contributing to increased landfill accumulation and polluting industrial emissions. Moreover, the cumulative effect of these inefficient processes leads to a significant increase in the carbon footprint of products throughout their entire lifecycle, from raw material procurement to post-production waste disposal.

[0003] In addition to environmental impacts, mechanical locking structures also have some functional defects. For example, rigid locking structures are susceptible to dimensional deviations, manufacturing tolerances, and installation wear, which can weaken the integrity of the interlocking structure.

[0004] Furthermore, over time or under stress, the boards may experience joint fatigue, leading to loosening of the locking system, edge chipping, and the formation of gaps. The most critical drawback is that the joints formed by mechanical locking are not waterproof. Despite the use of sealants, wax coatings, or edge banding impregnation, moisture can still penetrate the joints through capillary action. This is particularly problematic in bathrooms, kitchens, and commercial spaces with frequent humidity fluctuations. This moisture intrusion can cause the core layer to swell, delaminate, promote microbial growth, or permanently deform, severely damaging the structural and aesthetic performance of the flooring system. Summary of the Invention

[0005] In view of this, the present invention provides a sheet material that is beneficial to improving assembly performance in order to solve the above-mentioned technical problems.

[0006] A board material that improves assembly performance includes at least one core layer, at least one side disposed on the core layer, and at least one mechanical locking structure disposed on the side of the core layer. The core layer comprises natural fibers and an adhesive, wherein the natural fibers comprise 60% to 80% by weight and the adhesive comprises 20% to 40% by weight. At least a portion of the mechanical locking structure is a fungal inoculation zone and at least a portion is an antimicrobial zone.

[0007] Furthermore, the fungal inoculation area is coated with a composition for forming fungi.

[0008] Furthermore, the antibacterial area is coated with a fungal barrier agent.

[0009] Furthermore, the bio-based fungal material is one or more of the following: oyster mushroom, long-rooted oyster mushroom, and cladoceran.

[0010] Furthermore, after assembling at least two of the plates, the joint between the at least two plates is subjected to a heat treatment at a temperature greater than or equal to 80°C, so as to deactivate the bio-based fungal material and prevent it from growing.

[0011] Furthermore, the base material is one or more of at least one cellulose material, at least one mineral material, at least one polymer material, at least one foaming material, and at least one recycled material.

[0012] Furthermore, the board material also includes a decorative layer disposed on the core layer.

[0013] Furthermore, the plate also includes a wear-resistant layer disposed on the core layer.

[0014] Furthermore, the board material also includes a protective layer disposed on the core layer.

[0015] Furthermore, the plate also includes a coating layer disposed on the core layer.

[0016] Compared to existing technologies, the present invention provides a board material that offers superior assembly performance. At least a portion of the interlocking interface is embedded with an active interface, achieving coupling between adjacent boards through bio-guided growth. Compared to traditional interlocking systems relying on rigid synthetic components or engineered surfaces, this bio-active interlocking interface utilizes the biological behavior of active mycelia to simultaneously achieve structural coupling and functional enhancement. The bio-active interlocking interface incorporates directional selection materials such as mycelial inducers, which are selectively applied to the core layer, particularly along the sides. This directional selective growth behavior allows bio-based materials, such as one or more filamentous fungal strains like *Pleurotus ostreatus*, *Pleurotus ostreatus*, or *Cladosporium*, to form a molecularly interwoven mycelial structure, creating a seamless, flexible seam. This natural mycelial network can adapt to geometrical differences or surface irregularities without the need for adhesives, mechanical fasteners, or subtractive manufacturing processes. In addition to mechanical bonding, the inherent filamentous porous morphology of the mycelial microstructure within the sides provides significant sound and heat insulation, improving indoor space energy efficiency and sound insulation performance. In addition, the board is mainly made of biodegradable and circular economy compatible materials, designed to decompose naturally at the end of its life without leaving any harmful residues. Detailed Implementation

[0017] 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.

[0018] The present invention provides a sheet material that improves assembly strength. The sheet material that improves assembly strength includes at least one core layer, at least one side edge disposed on the core layer, and at least one mechanical locking structure disposed on the side edge.

[0019] To ensure the core layer possesses the general properties required of the board, such as strength, hardness, and elasticity, the materials used to make the core layer include base materials, such as at least one cellulose material, especially natural fibers. The cellulose material can be cellulose-based materials or plant-based fibers. The cellulose material can be kraft paper, wood chips, wood flour, long / short wood fibers, or combinations thereof. Plant-based fibers include mushroom fibers, cotton fibers, bamboo fibers, Manila hemp fibers, pineapple leaf fibers, or combinations thereof. The aforementioned cellulose materials can be used to make compressed wood products, such as medium-density fiberboard (MDF), oriented strand board (OSB), high-density fiberboard (HDF), cork, plywood, particleboard, etc. The aforementioned cellulose materials can also be used to make composite boards, such as stone-plastic composites (SPC) and wood-plastic composites (WPC).

[0020] In this application, the core layer is mainly composed of the base material and the adhesive. The base material, such as natural fiber, has a weight percentage content of 60% to 80%, the adhesive has a weight percentage content of 20% to 40%, and the total weight of the base material and the adhesive is 100.

[0021] The core layer, made from the base material and binder, is typically extruded using an extrusion machine. That is, the base material and binder are first mixed together as powders and then extruded. The binder includes, but is not limited to, conventional petroleum-based thermoplastics and / or renewable bioplastics. Conventional petroleum-based thermoplastics can be PP, PET, RPET, PVC, CPVC, CPE, etc. Renewable bioplastics can be, for example, PLA, PHA, PBS, PHU, CA, PET, PGA, PHA-V, PBAT, etc. The polymer binder can also be a starch-based bioplastic.

[0022] The density of the core layer made from the above-mentioned materials is typically 700-2100 kg / m³, preferably 1400-2000 kg / m³, more preferably 1500-1900 kg / m³, and even more preferably 1600-1800 kg / m³. The density of the core layer is preferably below 2000 kg / m³, more preferably below 1800 kg / m³. In a preferred but non-limiting embodiment, the density of the core layer is approximately 1700 kg / m³, with an average density deviation preferably ±50 kg / m³. Compared to SPC sheets with a density of approximately 2100 kg / m³, the core layer has a lower plastic content, such as approximately 20 wt% PVC, resulting in a weight reduction of up to 20% and improved transportation efficiency. Experimental testing also revealed that the core layer with a density of approximately 1700 kg / m³ exhibits superior sound insulation performance, with a ΔLw of 23 dB, which is better than that of traditional non-foamed SPC sheets. The density of traditional non-foamed SPC sheets is 2100 kg / m³, and the ΔLw is 18 dB. When the core layer with a density of approximately 1700 kg / m³ is compared with that of traditional foamed WPC sheets, experimental testing, according to ISO 23999 standards, demonstrates that the core layer exhibits superior dimensional stability, with a deformation rate of 0.01-0.05%, compared to 0.2-0.3% for the WPC control group and 950 kg / m³ for the WPX control group.

[0023] The mechanical locking structure can be the same as that used in traditional flooring and decorative panels, such as a tongue and groove structure or a click lock. These locking structures are designed to achieve rapid assembly and maintain structural interlocking between adjacent panels, and are existing technologies, so they will not be described in detail here. Traditional mechanical locking structures suffer from the drawback of rigid interfaces, relying on static dimensional fit for interlocking. Therefore, their performance can deteriorate due to uneven substrates, moisture expansion or thermal contraction, leading to loose joints, abnormal noises, and even mechanical separation over time. In addition, the joints between adjacent panels formed by hard, inelastic edges are particularly susceptible to moisture intrusion due to capillary action, which is more pronounced in high-humidity environments such as kitchens and bathrooms. Long-term water absorption can lead to swelling, surface peeling, and an increased risk of microbial growth, ultimately damaging the appearance and structural performance of the panels. In this invention, at least a portion of the mechanical locking structure is a fungal inoculation area and at least a portion is an antibacterial area.

[0024] The fungal inoculation area is coated with a composition for fungal formation, consisting of bio-based fungal material and a mycelial inducer. The bio-based fungal material can be one or more of *Pleurotus ostreatus*, *Trichoderma longifolia*, and *Cladosporium*. The core function of the mycelial inducer is to provide chemotaxis or trophotropism, meaning the mycelium senses the concentration gradient of these substances and grows towards higher concentrations. It is important to clarify that the mycelial inducer itself is not a binder. Its role is to "guide," and the final bonding strength is provided by the mechanical entanglement and bioadhesion of the grown mycelial network. The mycelial inducer includes, but is not limited to, sugars, starches, proteins, and lignocellulose materials. The sugars can be one or more of glucose and sucrose. The starches can be one or more of potato starch and corn starch. The proteins can be one or more of yeast extract and wheat bran. The lignocellulose materials can be one or more of pretreated sawdust and straw powder. Preferably, the mycelial inducer is uniformly mixed with the bio-based fungal material during the mixing of raw materials. The role of the mycelial inducer is to activate and guide the directional growth of mycelium through biological action. Therefore, the mycelial inducing agent is preferably located at the position of the mechanical locking structure, which can be applied by coating, while other positions are not affected. In this way, the mycelial inducing agent can achieve at least partial coupling connection between adjacent core layers.

[0025] Due to limitations in manufacturing equipment and processes, it is not possible to strictly place the bio-based fungal material solely on the mechanical interlocking structure. Therefore, at least a partial antimicrobial zone needs to be provided on the mechanical interlocking structure. This antimicrobial zone should be located near the surface of the core layer. A mycelial barrier agent is coated on this antimicrobial zone. The mycelial barrier agent is used to prevent mycelial growth on the surface of the core layer. Therefore, after the core layer is manufactured, the mycelial barrier agent needs to be applied to the surface of the core layer or at least a portion of the surface of the mechanical interlocking structure near the core layer. For example, the area near the core layer surface should be coated with the mycelial barrier agent to inhibit the growth of the bio-based fungal material on the core layer surface. Of course, it is conceivable that, sometimes, to prevent excessive growth on the mechanical interlocking structure, some mycelial barrier agent can be appropriately sprayed onto the fungal inoculation area of ​​the mechanical interlocking structure to ensure the integrity and precision of the mycelial connection after activation. The mycelial barrier agent has the opposite function to a mycelial inducer; it can hinder or inhibit mycelial growth. This mycelial barrier agent can prevent mycelial growth or force it away from areas in the board containing the mycelial barrier agent. The mycelial barrier agent can be strategically applied to specific areas of the board where mycelial growth is not desired, such as the top surface of the board to which the decorative layer is adhered. In some cases, the mycelial barrier agent is applied to virtually all surfaces of the core layer, except for at least one side where coupling connections are required. The mycelial barrier agent can be at least one compound, substance, or composition capable of inhibiting or preventing mycelial growth and migration into the portion of the board containing the mycelial barrier agent, such as a salt, fungicide, hydrophobic agent, etc.

[0026] When at least two panels are connected using the aforementioned mechanical locking structure, mycelium will grow towards the joint upon activation, forming a strong, flexible, and active mycelial connection. This mycelial connection can adapt to microscopic unevenness, improve sound and heat insulation performance, and achieve natural self-healing when damaged. Furthermore, due to the biodegradability and carbon sequestration capabilities of its material, this mycelial connection not only eliminates the need for synthetic fasteners but also supports environmental sustainability.

[0027] During assembly, at least two of the aforementioned boards are joined together using the mechanical interlocking structure. The bio-based fungal material forms a bioactive interlocking interface on the sides of the boards, which activates and guides the directional growth of mycelia between adjacent boards through biological action. This biological activation refers to the process of stimulating fungal mycelial growth and connection through environmental conditions such as humidity and temperature. The conditions for biological activation are that, after assembly, the necessary humidity for mycelial growth is provided through natural humidity or slight humidification, such as spraying water mist. During mycelial growth, the mycelia grow towards the joint under the guidance of a mycelial inducer, forming a fibrous network structure and achieving bio-coupling between the boards. When growth reaches a certain extent, such as when the joint between the two boards is completely filled with mycelia, growth should be terminated. Subsequent heat treatment, such as heating to above 80°C, deactivates the mycelia and stabilizes the connection structure.

[0028] The board material, which improves assembly performance, also includes at least one decorative layer. This decorative layer can be a digitally printed ink-absorbing layer. The printed pattern includes, but is not limited to, wood grain, ceramic tile, stone, slate, marble patterns, geometric shapes, floral patterns, abstract designs, or combinations thereof, to present a luxurious or natural visual effect. In a preferred embodiment, the printed pattern is printed on at least a partially stretchable carrier layer (such as a thermoplastic film) that supports the digitally printed pattern, allowing the decorative layer with the printed pattern to be laminated to the core layer.

[0029] The board material, which enhances assembly performance, also includes at least one wear-resistant layer. This wear-resistant layer has at least one textured structure that significantly improves the aesthetics and functionality of the board material (100) by enhancing safety, ergonomics, and user experience. The textured structure can be a single tactile feature or a combination of multiple textures, including but not limited to: glossy effects (such as smooth gloss or high-gloss glaze); matte effects (such as soft matte or textured matte); stone / wood grain textures; embossed patterns (such as geometric patterns, floral / leaf vein patterns, ribbed patterns); brushed / satin effects (such as brushed metal or satin stone patterns); anti-slip textures or soft-touch surfaces; marble effects (such as veined marble textures or imitation marble); concrete / ceramic finishes (such as polished concrete or rough concrete); metallic finishes (such as copper rust / bronze rust or stainless steel effects) and combinations thereof.

[0030] The board material that improves assembly performance also includes at least one protective layer. The material of the wear-resistant layer may contain at least one material with UV resistance, heat resistance, antiviral properties, antibacterial properties and / or antifungal properties, so that the wear-resistant layer has specific protective properties or functional characteristics.

[0031] The sheet material, which improves assembly performance, also includes at least one coating layer. The coating is composed of at least one polymer, such as a thermoplastic film or polymer layer. Preferably, the coating has at least one finish, including matte, ultra-matte, glossy, high-gloss, smooth, rough, or a combination thereof.

[0032] In contrast, the board material provided by this invention has its sides of the mechanical interlocking structure at least partially coated with a bio-based material, specifically a mycelium-based material in a filamentous morphology composed of mycelial structures. These sides achieve bioactive interlocking between adjacent boards through selective mycelial growth, a process biologically guided by embedded mycelial inducers and mycelial barrier agents. This mycelium-based material not only dynamically conforms to uneven areas of the substrate, enhancing the board's adaptability, but its natural fibrous structure also improves sound and heat insulation performance. After bio-mediated coupling, heat treatment can inactivate the mycelium, thereby stabilizing the seam while maintaining biodegradability. The heat treatment temperature is preferably greater than or equal to 80°C. After successful coupling, heat treatment, i.e., heating to a temperature greater than 80°C, can inactivate the active mycelium within the board, thereby stabilizing the seam and terminating subsequent bioactivity. Therefore, the integration of the functional biomaterial with the core layer and side design provided by this invention ultimately forms a system that reduces manufacturing waste, improves moisture resistance, and supports end-of-life composting, conforming to modern sustainability and circular design standards. The threshold temperature for heating can be determined based on the heat resistance of the furniture.

[0033] Compared to existing technologies, the present invention provides a board material that offers superior assembly performance. At least a portion of the interlocking interface is embedded with an active interface, achieving coupling between adjacent boards through bio-guided growth. Compared to traditional interlocking systems relying on rigid synthetic components or engineered surfaces, this bio-active interlocking interface utilizes the biological behavior of active mycelia to simultaneously achieve structural coupling and functional enhancement. The bio-active interlocking interface incorporates directional selection materials such as mycelial inducers, which are selectively applied to the core layer, particularly along the sides. This directional selective growth behavior allows bio-based materials, such as one or more filamentous fungal strains like *Pleurotus ostreatus*, *Pleurotus ostreatus*, or *Cladosporium*, to form a molecularly interwoven mycelial structure, creating a seamless, flexible seam. This natural mycelial network can adapt to geometrical differences or surface irregularities without the need for adhesives, mechanical fasteners, or subtractive manufacturing processes. In addition to mechanical bonding, the inherent filamentous porous morphology of the mycelial microstructure within the sides provides significant sound and heat insulation, improving indoor space energy efficiency and sound insulation performance. In addition, the board is mainly made of biodegradable and circular economy compatible materials, designed to decompose naturally at the end of its life without leaving any harmful residues.

[0034] 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 sheet material for facilitating assembly performance, characterized by: The board material for improving assembly performance comprises at least one core layer, at least one side edge arranged on the core layer, and at least one mechanical locking structure arranged on the side edge of the core layer, wherein the core layer comprises natural fibers and a binder, the weight percentage of the natural fibers is 60% to 80%, the weight percentage of the binder is 20% to 40%, and at least part of the mechanical locking structure is a fungus inoculation area and at least part of the mechanical locking structure is an antibacterial area.

2. The panel for improving assembly performance according to claim 1, wherein: The fungus inoculation area is coated with a composition for forming fungi.

3. The panel of claim 1, wherein: The antibacterial area is coated with a fungus barrier agent.

4. The panel for improving assembly properties according to claim 1, wherein: The bio-based fungal material is one or more of Pleurotus ostreatus, Oudemansiella radicata, and Cilioscypha.

5. The panel for facilitating assembly performance according to claim 1, wherein: After the assembly of at least two of the board materials is completed, the joint of the at least two board materials is subjected to a heating treatment at a temperature greater than or equal to ≥80℃ to inactivate the bio-based fungal material and prevent it from growing.

6. The panel for facilitating assembly performance according to claim 1, wherein: The base material is one or more of at least one cellulose material, at least one mineral material, at least one polymer material, at least one foamed material, and at least one recycled material.

7. The panel for facilitating assembly performance according to claim 1, wherein: The board material further comprises a decorative layer arranged on the core layer.

8. The panel for facilitating assembly performance according to claim 1, wherein: The board material further comprises a wear-resistant layer arranged on the core layer.

9. The panel for facilitating assembly performance according to claim 1, wherein: The board material further comprises a protective layer arranged on the core layer.

10. The panel for facilitating assembly performance according to claim 1, wherein: The board material further comprises a coating layer arranged on the core layer.

11. The panel for facilitating assembly performance according to claim 1, wherein: At least one of the core layers has a porosity of 10% to 25%.

12. The panel for facilitating assembly performance according to claim 1, wherein: The material for preparing the core layer further comprises a lignocellulose material that provides a carbon source for fungus growth.