Blocking panel and method for manufacturing the blocking panel

Abstract

The present invention relates to an insulation panel, particularly a wall or roof panel, having a foam core layer and a cover layer attached to the foam core layer. The present invention also relates to an insulation covering, particularly a wall or floor covering, including a plurality of such insulation panels.

Description

Technical Field

[0001] The present invention relates to a shielding panel, particularly a wall panel or a roof panel. The present invention also relates to a shielding cover, particularly a wall cover or a floor cover, including a plurality of the shielding panels. Further, the present invention relates to a method for manufacturing a shielding panel, particularly a wall panel or a roof panel.

Background Art

[0002] Typically, the insulating foam material is applied to the lower part of the floor covering, especially under a floating floor, or behind a wall covering, for example, as a thermal insulation layer and a sound insulation layer. The foam material can be either a closed-cell foam material or an open-cell foam material, and is typically at least partially made of polyurethane. Pre-constructed panels of solid foam material can be applied, but it is also conceivable that the insulating material is applied in a semi-liquid form by spraying. A topic of increasing concern regarding these materials is the migration of harmful and potentially volatile and semi-volatile substances, mainly due to recently improved or highly efficient buildings with restricted ventilation. Building materials that use (harmful) chemicals can affect the quality of the air inside the building and the health of people exposed to that air. A significant risk is seen during the installation or use of spray foam building materials, and (volatile) chemicals have been found to cause skin, eye, and lung inflammation, asthma, and chemical sensitization when absorbed through the skin or inhaled. Polyurethane is substantially stable in a fully reacted or cured state, and there are no major concerns regarding its chemical properties. However, some products such as adhesives, coating agents, and spray foams may react when incorporated by builders or homeowners and continue to react for several hours thereafter, potentially containing uncured isocyanates to which people may be exposed. Isocyanates such as methylene diphenyl diisocyanate are chemicals that react with polyols to form polyurethane and are known to be particularly toxic. Another issue with using polyurethane-based materials is the discussion regarding recyclability. Polyurethane generates toxic gases when incinerated, and there are several technical and economic difficulties associated with the physical and chemical recycling of polyurethane. Therefore, there is a need to replace all existing polyurethane-based foam materials with natural materials as renewable and naturally derived insulation layers. Summary of the Invention Problems to be Solved by the Invention

[0003] The first objective of the present invention is to provide a wood-based barrier panel as an alternative to a synthetic polymer-based barrier panel without the panel characteristics.

[0004] It is a second object of the present invention to provide an improved wood-based barrier panel.

[0005] It is a third object of the present invention to provide an improved wood-based barrier panel having properties improved over conventional polyurethane-based foam materials.

Means for Solving the Problems

[0006] At least one of these objectives can be achieved by providing a barrier panel, particularly a wall panel or a roof panel or a floor panel, · a core comprising at least one foamed core layer, said foamed core layer being at least partially made from a wood foam, and · at least one cover layer attached directly or indirectly to said foamed core layer, and a panel comprising the same.

[0007] There are several advantages to using a combination of a foamed core layer containing a wood foam and a cover layer attached to the foamed core layer. First, the advantages of the wood foam include having high fire resistance, excellent sound absorption or sound insulation, and good heat insulation while still being a completely wood-based material. Also, since the wood foam has a low density, it is a very lightweight material. Additionally, it has excellent moisture resistance and has been experimentally confirmed to have little bending or warping when immersed in water. Due to such characteristics of the wood foam, this material is particularly suitable as a heat insulation layer and / or a sound insulation layer for roof covers, ceiling covers, and / or wall covers. The wood foam is not a qualified composite material as it is based only on wood without mixing wood fibers with synthetic polymers such as PVC, PU, synthetic resins, or synthetic adhesives, and is different from wood polymer composite (WPC). The structure of the wood foam can be partially attributed to the natural chemical bonds between wood fibers that can be initiated by hydrogen peroxide added during the manufacturing process. However, sufficient mechanical strength cannot be obtained by these chemical forces alone. A second factor underlying the structure of the wood foam is the physical fixation and entanglement between the wood fibers (strands). For example, untreated wood fibers have a very smooth surface, but the fibers need to be roughened in order to achieve fixation. This can be done, for example, by polishing the substrate with a refiner that roughens the wood fibers until their surfaces are no longer smooth with respect to each other. By the natural chemical bonds of the roughened wood fibers, a wood foam with relatively high mechanical strength that can be manufactured without using an adhesive can be obtained. The wood foam usually has a substantially open-cell structure. The foamed core layer is preferably a waterproof layer. Both hardwoods and softwoods, as well as other lignocelluloses, are suitable raw materials for manufacturing the wood foam. In particular, the excellent heat insulation properties of this material are quite suitable for use as the material for the core layer of insulating panels, especially wall panels or roof panels. This suitability is enhanced by the high fire resistance of the material. In fact, in the event of a fire, the insulating panel will contribute to extinguishing the fire while smoldering. This is very advantageous both environmentally and in terms of safety.

[0008] The use of at least one cover layer that is directly or indirectly attached to the foamed core layer is beneficial because such a cover layer provides a protective function to the foamed core layer. Using both layers in the panel according to the present invention has several technical advantages. Since both the foamed core layer and the cover layer are relatively lightweight, such a combination results in a relatively lightweight panel suitable for applications in multiple construction fields. Due to the relatively high flexibility of the materials, it can be used as a curved or formed wall panel or, for example, as a ceiling panel. Also, because it is lightweight and has a low density, the load on the wall surface can be kept low, and it can also be used as an outer wall covering material. This may eliminate the need for conventional screw and / or nail connections, enabling the use of alternative connection systems and making installation easier. However, nailing and / or screwing the panel according to the present invention is possible. Furthermore, the combination of materials used is also suitable for, for example, sawing and gluing.

[0009] The material of the wood foam has several advantages of conventional natural materials. The advantages of the wood foam are that it has relatively high air permeability and can discharge the absorbed moisture in a controlled manner. Lack of air permeability is a common problem with conventional wood materials such as cedar or other softwoods, which can cause wood decay. The panel preferably includes natural materials in both the foam core layer and the cover layer, which is desirable from an environmental perspective. The cover layer typically provides a protective function for the wood foam foam core layer. The panel according to the present invention is contemplated for use both indoors and outdoors, and also for use in dry and wet areas (such as bathrooms) within the home. The foam core layer containing wood foam can equalize the surface level. This is particularly beneficial when used as a flooring material as it can eliminate the need for an additional underlayment, and can also be useful when applied to wall or roof structures. The wood foam of the foam core layer is preferably configured to obtain the desired sound insulation and / or heat insulation properties for building applications. Therefore, it is contemplated that the panel according to the present invention replaces the use of conventional floor, wall or ceiling panels having separate barrier (polyurethane) layers. A long product life is expected for the panel according to the present invention. However, even when the panel needs to be removed, its recycling is rather simple because at least the core layer of the panel is substantially wood-based. Furthermore, this panel provides a competitive priced product as an alternative to polyurethane-based products, especially for environmentally and health-sensitive consumers. In a further possible embodiment, it is contemplated that at least one foam core layer is manufactured substantially entirely from wood foam.

[0010] Typically, at least one foam core layer has a density of 30 kg / m 3 ~300 kg / m 3 and preferably 40 kg / m 3 ~250 kg / m 3has a density. Here, the mechanical strength varies depending on the density of the wood foam. The higher the density, the closer the fibers are to each other, and the binding and entanglement anchorages of the wood itself become stronger. Therefore, the higher the density, the higher the potential mechanical strength. However, due to the internal fixation of the wood foam, even at a relatively low density, it is possible to provide sufficient strength for a barrier panel while providing a fairly lightweight panel. Furthermore, for example, at least one foam core layer has a density of 30 kg / m 3 ~300 kg / m 3 , preferably 40 kg / m 3 ~250 kg / m 3 is conceivable. However, it is also conceivable that at least one foam core layer has a density of 40 kg / m 3 ~200 kg / m 3 , or 40 kg / m 3 ~150 kg / m 3 , or 40 kg / m 3 ~100 kg / m 3 . Also, it is conceivable that at least one foam core layer has a density between 30 kg / m 3 or 40 kg / m 3 and 70 kg / m 3 or 80 kg / m 3 .

[0011] As already shown above, in a preferred embodiment of the panel according to the invention, at least one foamed core layer is substantially free of resin, binder and / or adhesive. Such embodiments are beneficial as health concerns due to emissions from any of such additives can be eliminated. The foamed core layer preferably also contains no other (chemical) synthetic additives such as synthetic polymers. It is also conceivable that the foamed core layer consists only of wood foam, in particular wood fibers and / or wood strands. It is also beneficial that such a shielding panel is substantially free of resin, binder and / or adhesive. The wood foam of the foamed core layer typically consists of chemically bonded wood fibers, which are further bonded by physical fixation and entanglement of the wood fibers and / or strands of wood fibers.

[0012] In a possible embodiment, at least one cover layer of the shielding panel is at least partially made of densified wood. With regard to the cover layer which may contain densified wood, the use of such a material layer has several advantages. Densified wood considerably improves the mechanical properties of wood. Densified wood can be obtained by an engineering process, an example of which is shown below. Technically, it is possible to compress wood up to 20% of its original thickness, as a result of which so-called complete densification can be achieved. Densification as meant within the scope of the present invention is usually compressed to at least 50%, preferably at least 40%, more preferably at least 30% of its original thickness. For the purpose of obtaining such densified wood, natural wood is first treated with NaOH / Na 2 SO 3It is boiled in a solution. Then, the wood is compressed at a temperature of at least 100 °C perpendicular to the growth direction of the wood. In this process, the hemicellulose and lignin (the harder components of the wood), which are adhesives that usually connect the wood cells, are partially removed. If these are completely removed, it may result in a poor-quality material, suggesting that lignin is still necessary to bond the wood. The cellulose of the wood remains intact, and hydrogen bonds between the closely spaced cellulose nanofibers enhance the strength of the densified wood. Therefore, the densified wood of the cover layer is preferably composed of chemically treated and compressed wood. Preferably, the densified wood of the cover layer contains less than 10% by weight of hemicellulose and / or less than 15% by weight of lignin. The densified wood obtained by this process is a fairly stable type and is not affected even under humidity conditions, so it is suitable for use in ceilings and ceiling structures, as well as for example, floor materials. Also, in addition to the excellent mechanical properties of this material, the densified wood is a relatively lightweight material, which is beneficial for construction purposes. The densified wood is also suitable as a cover layer due to its relatively high scratch resistance. Instead of the term "densified wood", the term "compressed wood" can also be used. The densified wood can be radially densified wood and / or tangentially densified wood. Preferably, the densified wood of the cover layer is at least partially composed of hardwoods such as hinoki, balsa, beech, hickory, mahogany, maple, oak, teak, walnut, oak, and / or poplar. The hardwood used to create the cover layer is preferably obtained from angiosperms (or flowering plants) that are not monocotyledons. Usually, the densified wood has waterproof properties. Therefore, the cover layer is preferably a waterproof layer. For example, it is also conceivable that at least one cover layer is substantially entirely made of densified wood.

[0013] In particular, when a consolidated wood layer is applied as the cover layer, an embodiment in which at least one foam core layer and at least one cover layer are fused together can be considered. In this way, the use of adhesives and / or binders and / or binding materials can be omitted. Since both the foam core layer and the cover layer contain wood-based materials, it is possible to fuse the layers together. The fusion can be, for example, heat fusion performed by applying heat. The fusion of the core layer and the cover layer typically results in a strong and firm connection between the layers. Also, the change in delamination can be significantly reduced. However, it is still imaginable that the cover layer is adhered to the foam core layer.

[0014] It is also conceivable that at least one cover layer is made at least partially of a metallic material. By the cover layer being made at least partially of a metallic material, a protective function for the wood foam can be provided. For example, it is conceivable that the wood foam core layer is coated with a metallic material. For example, it is also possible for the (partial) metallic cover layer to be relatively rigid (e.g., a metal sheet) so that the metallic cover layer can form at least part of a metal casing. In that case, the shielding panel can be easily structured at least partially. At least one surface of the panel can, for example, have a structured pattern. This gives rise to the possibility, for example, of using the panel as a roof panel. The use of a cover layer made at least partially of a metallic material makes it possible to easily incorporate (interconnect) connecting parts. It is also conceivable that at least one cover layer contains a metal foil. Non-limiting examples of metal foils are aluminum foil, tin foil, metal foil and / or composition leaf. The presence of the metal foil can further enhance the shielding properties of the panel. Another possibility is the presence of at least one cover layer made at least partially of natural fibers. Non-limiting examples are bamboo, hemp, linen, flax, jute, sisal, coconut and / or banana fibers. The natural fibers can, for example, be present at least partially in the form of a (woven) mat. Depending on the type used, the natural fibers can have the advantage of good water repellency, good elasticity, good thermoregulation properties, and / or bacteriostatic properties. Furthermore, natural fibers usually have the advantage of a good ecological footprint due to their high sustainability and low pollutability. Thus, the combination of wood foam and natural fibers can contribute to environmentally friendly properties and / or ease of recycling of the panel.

[0015] The foam core layer can comprise at least one support structure. Such a support structure can, for example, contribute to and / or support the spatial orientation of the foam core layer as a distance element. For example, it is possible for at least one support element to be substantially embedded within the foam core layer.

[0016] The wood foam can be, for example, an open-cell foam. The open-cell foam structure of the wood foam can contribute to the air permeability of the foam core layer and thus to the air permeability of the barrier panel. However, it is also conceivable that the wood foam is a closed-cell foam. It is further conceivable that at least one foam core layer includes a wood foam made from a single type of wood. The advantage of using a wood foam made from a single type of wood is that the manufacturing cost may be reduced. It is also possible to use multiple types of wood in the manufacture of the wood foam. As already shown above, the wood foam can be made from, for example, softwood or hardwood, or a combination of both. Non-limiting examples of types of wood that can be used for making the wood foam for use in the foam core layer include beech wood and / or pine wood.

[0017] The panel can include a plurality of foam core layers, where each foam core layer can include a wood foam. In such an embodiment, each foam core layer can have a different density. Providing a panel that includes a plurality of foam core layers, each having a wood foam, can be beneficial because material properties such as rigidity can be relatively easily adapted. The plurality of foam core layers can be interconnected, for example, via a fusing process. The advantage is that the use of adhesives can be avoided. In a further possible embodiment, the panel can preferably include at least one intermediate layer surrounded between at least two foam core layers, where the intermediate layer more preferably includes consolidated wood. This configuration makes it possible to construct a lightweight panel having the aforementioned damping and barrier properties and having a (substantially) rigid spine for adding torsional hardness and rigidity.

[0018] As mentioned above, the core preferably includes at least one intermediate layer. By adding one or more intermediate layers to the core, typically, the acoustic and / or structural properties of the core, and thus the acoustic and / or structural properties of such a panel, are improved. Preferably, at least one intermediate layer is at least partially surrounded by at least one foamed core layer. More preferably, at least one, preferably each, intermediate layer is substantially entirely surrounded by other core materials, particularly one or more foamed core layers. Preferably, at least one intermediate layer is embedded within a foamed core layer or between two adjacent foamed core layers of the core. Preferably, the intermediate layer is configured to function as a reinforcing layer. This facilitates adapting the panel for use as a roof panel, wall panel, or floor panel. Also, this facilitates profiling the panel edge, particularly adapting the panel for interconnecting with other panels. Preferably, at least one intermediate layer includes interconnected fibers. More preferably, the intermediate layer forms a fiber mat, which can be a woven or non-woven mat. Typically, the fibers are interconnected by a resin such as a thermosetting resin. Preferably, the intermediate layer includes (synthetic) fibers selected from the group consisting of glass fibers, carbon fibers, and / or aramid fibers. Preferably, the intermediate layer includes natural fibers selected from the group consisting of flax, jute, hemp, abaca, ramie, cellulose, and / or kenaf. Thus, preferably, at least one intermediate layer is an open layer and / or a porous layer, preferably a woven or non-woven mat. Preferably, at least one foamed core layer penetrates the intermediate layer or at least a part of the pores present in the intermediate layer. It is conceivable that the core includes at least two foamed core (sub) layers interconnected via the through holes of the intermediate layer. Preferably, the core has a thickness T, and the core includes a plurality of embedded reinforcing layers, particularly glass fiber layers, located on both sides of the center line defined by 0.5T of the core. When a single intermediate layer is applied, this intermediate layer can be arranged on the center line of the core.Alternatively, the single intermediate layer may be disposed on top of (which is usually preferred) or below the core.

[0019] Preferably, during the manufacture of the panel, at least one intermediate layer is disposed in an aqueous wood pulp that is converted into a wood foam-based foam core layer, and then the wood pulp is dried and converted into the foam core layer, resulting in a foam core layer with the intermediate layer embedded therein. This can also be regarded as a preferred embodiment where the core comprises a plurality of integrally connected foam layers incorporating at least one intermediate layer.

[0020] Preferably, the manufacture of the wood foam-based foam core layer is carried out by shaving the wood and then grinding the wood until wood flour is formed. Adding water and heating this mixture usually results in wood pulp. This suspension containing lignocellulose further contains hemicellulose and lignin and usually also wood residues. This residue fraction can then be activated to function as a binder (adhesive) for binding wood particles / fibers during drying. Foaming the suspension into a foam is usually done by a foam stabilizer such as a protein, as well as by aerating the suspension and drying the suspension at a temperature usually in the range of 80 - 140°C. This process is very suitable for introducing at least one intermediate layer into the suspension and embedding the intermediate layer in the final foam core layer during foaming and drying.

[0021] Instead of an open intermediate layer, the core may also optionally additionally include at least one closed intermediate layer. It is conceivable that the intermediate layer is at least partially made of compacted wood.

[0022] Preferably, at least one foamed core layer has a thickness of 0.5 to 20 cm, preferably 1 to 15 cm, more preferably 2 to 10 cm. The foamed core layer according to the present invention having such a thickness has good barrier properties while it has been experimentally found that it gives sufficient stability to such panels. Depending on the desired application and the desired material properties, the thickness of the foamed core layer can be selected. A relatively thick foamed core layer can provide, for example, improved (thermal) barrier properties.

[0023] Typically, the cover layer has a density of at least 800 kg / m 3 , preferably at least 900 kg / m 3 , more preferably at least 1000 kg / m 3 The density of the cover layer is usually substantially higher than the density of at least one foamed core layer. The cover layer can have a thickness of 1 to 7 mm, preferably 2 to 5 mm. However, when a (metal) foil is used as the cover layer, its thickness can be less than 1 mm. The cover layer can be adhered to the foamed core layer. Thus, at least one foamed core layer and at least one cover layer can be adhered together. When applying an adhesive, preferably, natural and / or non-toxic adhesives are used. Such natural adhesives can be made, for example, from organic sources such as natural resins and dextrin.

[0024] At least one cover layer can have an upper surface area that extends beyond the upper surface of the foamed core layer. Alternatively, the cover layer can be attached to the foamed core layer at an offset position. Both options usually make it easier to profile one or more edges, preferably the edges of the cover layer, to enable the interconnection of the panels during installation. In fact, it is also possible for the panel according to the present invention to include at least one pair of opposing side edges with interconnection coupling means. Such interconnection coupling means can be, for example, a combination of a tongue and a groove. The interconnection coupling means can be provided on at least one foamed core layer and / or at least one cover layer.

[0025] In other beneficial embodiments, the panel includes at least two cover layers that are directly or indirectly attached to the opposite side of at least one foamed core layer. Thus, basically, a sandwich structure can be obtained in which at least one foamed core layer is substantially surrounded by at least two cover layers. It is also conceivable that the foamed core layer is substantially surrounded by the cover layer. In such embodiments, the cover layer can further impart its protective function.

[0026] In a preferred embodiment, at least one cover layer is directly or indirectly attached over at least one foamed core layer. Here, when applied, the decorative upper surface can preferably be at least partially formed by the cover layer. A protective coating can be used to protect the cover layer. Especially when the cover layer contains consolidated wood, such a protective coating can be an oil-based coating. It is also conceivable to apply an oil-based coating to the cover layer. By applying an oil-based coating to the cover layer, the dimensional stability of the cover layer can be improved. Consolidated wood may become slightly weaker or swell under extreme high humidity conditions such as a humidity of about 95%. The oil-based coating can prevent this swelling and provide a protective coating for the cover layer. It is also conceivable that at least one foamed core layer is directly or indirectly attached over at least one cover layer.

[0027] In addition, the panel may preferably include a decorative upper substrate that is directly or indirectly attached onto the cover layer and / or the foam core layer, where the decorative upper substrate preferably constitutes the decorative upper surface of the panel. The upper substrate may be composed of a single layer or may be composed of multiple layers. Preferably, when applied, the upper substrate comprises at least one printed layer and / or at least one protective (upper) layer covering the printed layer. The presence of the printed layer and / or the protective layer can prevent the panel, particularly the cover layer, from being scratched and / or from being damaged by environmental factors such as ultraviolet rays / moisture and / or abrasion. When the cover layer contains densified wood, it is also conceivable that an oil-based coating is applied to the densified wood cover layer before at least one printed layer and / or protective layer is applied. The printed layer can be formed by a film with a decorative print, where the film is attached onto the cover layer and / or the foam core layer. The printed layer can also be formed by at least one ink layer that is directly applied onto the cover layer, the upper surface of the foam core layer, or onto a primer layer applied onto the cover layer and / or the foam core layer.

[0028] In another possible embodiment, the blocking panel may include at least one backing layer attached to the lower side of the foam core layer. The backing layer may provide stability and / or protection to the panel, for example. The backing layer may include, for example, a porous natural layer, particularly porous cellulose. The use of a porous cellulose backing layer allows for the evaporation of moisture from the foam core layer containing the wood foam during the manufacturing process, while the (semi) porous backing layer can come into contact with a part of a wall, ceiling, or roof structure, bringing advantages regarding the breathability of the panel. The presence of such a porous backing layer may make it possible to absorb more convective heat radiation to the foam core layer containing the wood foam. Also, another natural fiber material may be applied as the backing layer, for example, but not limited to, a non-woven fabric structure based on PLA. However, the backing layer may also be a non-porous natural layer, preferably a non-porous vapor barrier layer. A possible non-limiting example of such a layer is non-porous cellulose. The non-porous backing layer can prevent moisture from entering the foam core layer containing the wood foam in areas where a relatively high level of moisture is present (e.g., a bathroom). Both the porous backing material and the non-porous backing material will need to be made from heat-resistant or crystalline structures, preferably bio-based materials, to withstand the drying conditions used in the manufacture of the foam core layer containing the wood foam.

[0029] At least one foamed core layer may contain at least one mineral material, in particular concrete. Using at least one mineral material as a filler in the foamed core layer may reduce the water absorption of the foamed core layer. For example, 5 to 15% by weight of the mineral material may be applied in the foamed core layer. Wood foam is susceptible to water absorption, which is undesirable as it may promote fungal attack. In particular, the use of at least one mineral material in such an amount may significantly reduce the water absorption of the wood foam. Using at least one mineral material in the foamed core layer may also result in a higher density of the foamed core layer. Instead of the mineral material, it is also conceivable that at least one hydrophobic additive such as silane and / or wax is applied. However, the hydrophobic additive will have an adverse effect on the strength of the foamed core layer.

[0030] Preferably, each layer of the panel is a substantially waterproof layer. Preferably, such a decorative panel is a waterproof panel. Preferably, the barrier panel itself is a thermally stable (heat-resistant) panel.

[0031] In a preferred embodiment of the decorative panel according to the invention, the panel does not include a cover layer. In another preferred embodiment of the barrier panel according to the invention, the panel does not include any wood foam-based foamed core layer.

[0032] Preferably, at least one panel layer, in particular at least one foamed core layer and / or at least one decorative cover layer, contains at least one antibacterial agent and / or is coated with at least one antibacterial agent. One or more antibacterial agents incorporated inhibit the growth of bacteria, fungi, microorganisms and other pathogens or non-pathogens and typically migrate to the tile surface over time, thereby establishing a concentration gradient that controls the growth of microorganisms upon contact with the tile surface. Preferably, the antibacterial agent is selected from (i) organic antibacterial substances or organometallic antibacterial substances such as halogenated phenyl ethers, halogenated salicylanilides, sesquiterpene alcohols, halogenated carbanilides, bisphenol compounds, general phenols, formaldehyde, quaternary ammonium compounds, pyridine derivatives and hexachlorophene, and / or (ii) inorganic antibacterial substances containing silver, zinc or copper in a glass or ceramic matrix, where the antibacterial agent preferably contains 2,4,4'-trichloro-2'-hydroxydiphenyl ether. The antibacterial agent may also be a chemical selected from the group consisting of triclosan, orthophenylphenol, diiodomethyl p-tolyl sulfone, zinc pyrithione, sodium pyrithione, azoles such as propiconazole, poly(hexamethylene biguanide) hydrochloride, 3,4,4'trichlorocarbanilide, barium mono hydrate, and silver, copper, or zinc in zeolite or amorphous glass powder. During the manufacture of the foamed layer, it is imaginable and rather realistic to mix at least one antibacterial agent with the wood foam (or the precursor wood pulp suspension).

[0033] The invention further relates to a shielding cover, in particular a shielding wall cover, a shielding ceiling cover, or a shielding roof cover, or a shielding floor cover, comprising a plurality of shielding panels according to the invention. As shown above, due to the relatively high flexibility of the layer, the cover can be applied in a curved or shaped configuration.

[0034] The present invention further relates to a method for manufacturing a shielding panel, particularly a wall panel or a roof panel, preferably according to the present invention, the method comprising: a) providing at least one foamed core layer comprising an upper part and a lower part, said foamed core layer comprising a wood foam; b) providing at least one decorative cover layer comprising compacted wood; and c) attaching at least one cover layer to the upper part and / or the lower part of said foamed core layer. The method includes the above steps.

[0035] Embodiments of the present invention are further shown in the following non-limiting list of items.

[0036] 1. A shielding panel, particularly a wall panel, a roof panel, or a floor panel, comprising: · a core comprising at least one foamed core layer, said foamed core layer being at least partially made of a wood foam; and · at least one cover layer directly or indirectly attached to said foamed core layer. The panel includes the above components.

[0037] 2. The panel according to item 1, wherein at least one foamed core layer has a density of 30 kg / m 3 to 300 kg / m 3 preferably 40 kg / m 3 to 250 kg / m 3 3. The panel according to any one of items 1 or 2, wherein at least one foamed core layer substantially does not contain a resin, a binder, and / or an adhesive.

[0038] 4. The panel according to any one of items 1 to 3, wherein at least one foamed core layer substantially does not contain a synthetic polymer.

[0039]

[0040] ​5. The wood foam of the foamed core layer is composed of chemically bonded wood fibers, and the wood fibers are further bonded by physical fixing and entanglement of wood fibers and / or strands of wood fibers. The panel according to any one of claims 1 to 4.

[0041] 6. The panel according to any one of claims 1 to 5, wherein at least one cover layer is at least partially made of consolidated wood.

[0042] 7. The panel according to any one of claims 1 to 6, wherein at least one cover layer is at least partially made of a metallic material.

[0043] 8. The panel according to any one of claims 1 to 7, wherein at least one cover layer contains a metal foil.

[0044] 9. The panel according to any one of claims 1 to 8, wherein at least one cover layer is at least partially made of natural fibers.

[0045] 10. The panel according to any one of claims 1 to 9, wherein the foamed core layer includes at least one support structure.

[0046] 11. The panel according to any one of claims 1 to 10, wherein the wood foam is an open-cell foam.

[0047] 12. The panel according to any one of claims 1 to 11, wherein the panel includes a plurality of foamed core layers, and each foamed core layer includes a wood foam.

[0048] 13. The panel according to any one of claims 1 to 12, wherein the core includes at least one intermediate layer.

[0049] 14. The panel according to claim 13, wherein at least one intermediate layer is at least partially surrounded by at least one foamed core layer.

[0050] 15. The panel according to claim 13 or 14, wherein at least one intermediate layer is embedded within the foamed core layer or between two adjacent foamed core layers.

[0051] 16. The panel according to any one of claims 13 to 15, wherein the intermediate layer is configured to function as a reinforcing layer.

[0052] 17. The panel according to any one of claims 13 to 16, wherein the intermediate layer comprises interconnected fibers.

[0053] 18. The panel according to any one of claims 13 to 17, wherein the intermediate layer comprises fibers selected from the group consisting of glass fibers, carbon fibers, and / or aramid fibers.

[0054] 19. The panel according to any one of claims 13 to 18, wherein the intermediate layer comprises natural fibers selected from the group consisting of linen, jute, hemp, abaca, ramie, cellulose, and / or kenaf.

[0055] 20. The panel according to any one of claims 13 to 19, wherein the intermediate layer is an open layer and / or a porous layer, preferably a woven or non-woven mat.

[0056] 21. The panel according to any one of claims 13 to 20, wherein at least one foamed core layer penetrates the intermediate layer.

[0057] 22. The panel according to any one of claims 13 to 21, wherein the core comprises at least two foamed core layers interconnected via through-holes in the intermediate layer.

[0058] 23. The panel according to any one of claims 13 to 22, wherein the core comprises a plurality of integrally connected foamed layers incorporating at least one intermediate layer.

[0059] 24. The panel according to any one of claims 13 to 23, wherein the core has a thickness T, and wherein the core includes a plurality of embedded reinforcing layers, in particular glass fiber layers, located on both sides of a center line defined at 0.5T of the core.

[0060] 25. The panel according to any one of claims 13 to 24, wherein the core includes at least one closed layer.

[0061] 26. The panel according to any one of claims 13 to 25, wherein the intermediate layer is at least partially made of consolidated wood.

[0062] 27. The panel according to any one of claims 1 to 26, wherein at least one foamed core layer has a thickness of 0.5 to 20 cm, preferably 1 to 15 cm, more preferably 2 to 10 cm.

[0063] 28. The panel according to any one of claims 1 to 27, wherein the cover layer has a density of at least 800 kg / m 3 , preferably at least 900 kg / m 3 , more preferably at least 1000 kg / m 3 .

[0064] 29. The panel according to any one of claims 1 to 28, wherein the cover layer has a thickness of 1 to 10 mm, preferably 2 to 7 mm.

[0065] 30. The panel according to any one of claims 1 to 29, wherein at least one foamed core layer and at least one cover layer are fused together.

[0066] 31. The panel according to any one of claims 1 to 30, wherein at least one foamed core layer and at least one cover layer are adhered together.

[0067] 32. The panel according to any one of claims 1 to 31, wherein the cover layer has an upper surface area that exceeds the upper surface of the foamed core layer.

[0068] 33. The panel according to any one of claims 1 to 32, comprising at least two cover layers directly or indirectly attached to the opposite side of the upper part of the at least one foamed core layer.

[0069] 34. The panel according to any one of claims 1 to 33, comprising at least one pair of opposing side edges with interconnecting coupling means.

[0070] 35. The panel according to any one of claims 1 to 34, wherein at least one foamed core layer comprises a mineral material, in particular concrete.

[0071] 36. The panel according to any one of claims 1 to 35, wherein each layer of the panel is substantially a waterproof layer.

[0072] 37. The panel according to any one of claims 1 to 36, wherein the panel does not include a cover layer.

[0073] 38. The panel according to any one of claims 1 to 37, wherein the panel does not include a foamed core layer based on wood foam.

[0074] 39. A shielding cover, in particular a wall cover or a floor cover, comprising a plurality of shielding panels according to any one of claims 1 to 38.

[0075] 40. A method for manufacturing a shielding panel, in particular a wall panel or a roof panel, preferably according to any one of claims 1 to 38, comprising: a) providing at least one foamed core layer comprising an upper part and a lower part, wherein the foamed core layer comprises wood foam; b) providing at least one decorative cover layer comprising compacted wood; and c) attaching at least one cover layer to the upper part and / or the lower part of the foamed core layer. The method comprising the steps.

[0076] The present invention will be described based on the following non-limiting exemplary embodiments shown in the drawings.

Brief Description of the Drawings

[0077]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Modes for Carrying Out the Invention

[0078] FIG. 1 shows a shielding panel 100 including a foam core layer 101 at least partially made of a wood foam and a cover layer 102 attached to the foam core layer 101. The panel 100 can be used, for example, as a wall panel or a roof panel. The foam core layer 101 includes an upper portion 101a and a lower portion 101b. The cover layer 102 is attached to the upper surface 101a of the foam core layer 101. The foam core layer 101 includes a wood foam, and the wood foam preferably has a substantially open-cell structure. The cover layer 102 includes densified wood. In the illustrated embodiment, the cover layer 102 is directly attached to the foam core layer 101, particularly through fusion.

[0079] Figure 2 is a perspective view showing a second possible embodiment of the shielding panel 200 according to the present invention. The panel 200 includes a wood foam core layer 201 and two cover layers 202a, 202b. The core layer 201 is actually substantially surrounded between the cover layers 202a, 202b. In the illustrated embodiment, the cover layers 202a, 202b are made of a metallic material. Accordingly, the wood foam of the foam core layer 201 is shielded by the cover layers 202a, 202b. The metallic cover layers 202a, 202b actually form a metallic casing surrounding the core layer 201. Each cover layer 202a, 202b has an upper surface area exceeding the upper surface of the foam core layer 201. The panel 200, particularly the cover layers 202a, 202b, is provided with interconnecting and coupling means 203 that enable easy installation of the panel. The panel 200 of the illustrated embodiment has a structured upper surface, and the lower surface of the panel is also slightly structured. This can also contribute to the ease of use of the shielding panel 200, for example, in applications as a roof panel 200.

[0080] Figure 3 is a cross-sectional view showing a third possible embodiment of the shielding panel 300 according to the present invention. The panel 300 includes a foam core layer 301 containing a wood foam and a cover layer 302 attached to the foam core layer via an adhesive layer 304. Optionally, the panel 300 includes a backing layer 305 attached to the lower side portion of the foam core layer 301. Also optionally, the panel 300 may include a printed layer 306 and / or at least one protective layer 307.

[0081] Figure 4 is a cross-sectional view showing a fourth possible embodiment of the shielding panel 400 according to the present invention. A foam core layer 401 containing a wood foam is attached to a cover layer 402 made of a metal foil. It can be seen that the thickness (d)f of the foam core layer 401 is substantially greater than the thickness (d)c of the cover layer 402.

[0082] Figure 5 is a cross-sectional view showing a fifth possible embodiment of a shielding panel 500 according to the present invention. The panel 500 includes a cover layer 502. The panel 500 also includes at least one intermediate layer 508 surrounded between two foam core layers 501a, 501b. The intermediate layer 508 includes consolidated wood and / or a fiber-based reinforcing layer and may have an interconnected shape (not shown). The intermediate layer 508 may also include another natural material, for example, preferably interconnected natural fibers selected from the group consisting of flax, jute, hemp, abaca, ramie, cellulose, and / or kenaf.

[0083] Instead of natural fibers, synthetic fibers such as glass fibers, carbon fibers, and / or aramid fibers may also be used. Optionally, the intermediate layer 508 preferably includes interconnected fibers and forms an open layer and / or a porous layer, preferably a woven or non-woven mat, that penetrates one or both of the foam core layers 501a, 501b. Preferably, the foam core layers 501a, 501b are interconnected through through-holes formed in the intermediate layer 508. In this embodiment, it is shown that the intermediate layer 508 is located on the center line of the core of the panel 500, and the core is formed by a laminate of the lower foam core layer 501b, the intermediate layer 508, and the upper foam core layer 501a.

[0084] The above-described inventive concepts are illustrated by several exemplary embodiments. When applying an individual inventive concept, it is considered possible that the individual inventive concept may be applied without applying the other details of the examples described above. Those skilled in the art will understand that they can combine numerous inventive concepts to conceive specific applications, so it is not necessary to detail all possible combinations of the above-described inventive concepts.

[0085] The present invention is not limited to the embodiments illustrated and described herein, and it will be apparent that numerous modifications are possible within the scope of the appended claims that will be apparent to those skilled in the art. When the term "insulated panel" is used, it may also be referred to as an "insulating panel". The insulated panel according to the present invention is typically also suitable for use as a floor panel.

[0086] As used in this patent publication, the verb "comprising" and its conjugations are understood to mean not only "including", but also the phrases "containing", "consisting essentially of", "formed by" and their conjugations.

Claims

1. A blocking panel, comprising: a core including at least one foamed core layer, wherein the foamed core layer is at least partially made of a wood foam, and the core includes at least one intermediate layer; at least one cover layer directly or indirectly attached to the core; wherein at least one intermediate layer is at least partially surrounded by at least one foamed core layer; wherein at least one intermediate layer is embedded within a foamed core layer or between two adjacent foamed core layers; wherein the intermediate layer is configured to function as a reinforcing layer; wherein the intermediate layer includes fibers selected from the group consisting of glass fibers, carbon fibers, and / or aramid fibers; a panel, wherein at least one foamed core layer penetrates through the intermediate layer.

2. The panel according to claim 1, wherein the intermediate layer includes natural fibers selected from the group consisting of linen, jute, hemp, abaca, ramie, cellulose, and / or kenaf.

3. The panel according to claim 1 or 2, wherein the core includes at least two foamed core layers interconnected through through-holes of the intermediate layer.

4. The panel according to any one of claims 1 to 3, wherein the core has a thickness T, and the core includes a plurality of embedded reinforcing layers located on both sides of a center line defined by 0.5T of the core.

5. At least one foam core layer has a strength of 30 kg / m ３ ~300kg / m ３ 5. The panel according to claim 1 , having a density of:

6. The panel according to any one of claims 1 to 5, wherein the wood foam of the foamed core layer is composed of chemically bonded wood fibers, and the wood fibers are further bonded by physical fixing and entanglement of wood fibers and / or strands of wood fibers.

7. The panel according to any one of claims 1 to 6, wherein at least one foamed core layer has a thickness of 0.5 to 20 cm.

8. The panel according to any one of claims 1 to 7, wherein the cover layer has a density of at least 800 kg / m3.

9. The panel according to any one of claims 1 to 8, wherein the cover layer has a thickness of 1 to 10 mm.

10. The panel according to any one of claims 1 to 9, wherein at least one foamed core layer and at least one cover layer are adhesively bonded together.

11. The panel according to any one of claims 1 to 10, comprising at least one pair of opposing side edges provided with means for mutual connection and bonding.

12. The panel according to any one of claims 1 to 11, wherein each layer of the panel is a waterproof layer.

13. The panel according to any one of claims 1 to 12, wherein at least one of each layer of the panel contains at least one antibacterial agent and / or is coated with at least one antibacterial agent.

14. A shielding cover including a plurality of shielding panels according to any one of claims 1 to 13.

15. A method of manufacturing a shielding panel according to any one of claims 1 to 13, comprising: a) providing at least one foamed core layer including an upper portion and a lower portion, the foamed core layer including a wood foam; b) providing at least one decorative cover layer including compacted wood; and c) attaching at least one cover layer to the upper portion and / or the lower portion of the foamed core layer.

Images