Abstract:
Building boards and method for manufacturing the same are provided. The building board comprises a cement layer ( 102 ) and a magnesium oxide layer ( 104 ). The method for manufacturing the building board comprises the steps of providing a cement board and a magnesium oxide board, dehydrating and binding the cement board and the magnesium oxide board. The performance of moisture proofing, fungus proofing, erode proofing, fireproof and others can be improved by utilizing the building boards.

Description:
TECHNICAL FIELD 
       [0001]    This invention relates generally to the field of building decoration materials technology, and more particularly to a building board and the method for manufacturing the same. 
       BACKGROUND OF THE INVENTION 
       [0002]    A conventional building board, such as laminate flooring, comprises 2 or 3 wooden layers to make the flooring stable. For 3-layer wooden building boards, an outer layer is generally made of wooden material having certain wood grain patterns, and the surface thereof can be further coated with paints to improve the decorative effect; and an inner layer is normally made of wooden layers with plywood structure or other cheaper woods. The wooden layers of the inner layer provide effects of buffering and soundproofing, thus it further improves user experience. 
         [0003]    However, in practical applications, the building board made of wooden layers is easy to corrode and deform after water ingress or wetting, or deform under humid conditions, and therefore the user experience is affected. Moreover, the manufacturing of wooden building board needs a huge amount of wood with high-energy consumption, which could severely destroy the natural environment. 
       SUMMARY OF THE INVENTION 
       [0004]    There is a need to provide a building board that features erode proofing, free of deformation, and more environment-friendly. 
         [0005]    Accordingly, in an embodiment of the present invention, a building board is provided, and the building board comprises a cement layer and a magnesium oxide layer. 
         [0006]    Alternatively, the cement layer and the magnesium oxide layer are bound with glue. 
         [0007]    Alternatively, the cement layer comprises cement and glass fiber. 
         [0008]    Alternatively, the cement layer has a thickness from 2 to 20 millimeters. 
         [0009]    Alternatively, the magnesium oxide layer has a thickness from 8 to 15 millimeters. 
         [0010]    Alternatively, the cement layer has a density from 1.1 to 1.8 g/cm 3 . 
         [0011]    In another embodiment of the present invention, a laminate flooring is provided. The laminate flooring comprises a cement layer and a magnesium oxide layer. 
         [0012]    Alternatively, the laminate flooring further comprises a buffer layer, wherein the buffer layer is connected with the magnesium oxide layer. 
         [0013]    Alternatively, the buffer layer comprises rubber or plastics. 
         [0014]    Alternatively, the laminate flooring is shaped as square, rectangle, parallelogram, hexagon or octagon. 
         [0015]    Alternatively, the laminate flooring is covered with a protective coating. 
         [0016]    Alternatively, the protective coating is oil or varnish. 
         [0017]    Alternatively, each side of the laminate flooring has tongue or groove to joint to each other, or has click system to joint to each other. 
         [0018]    In a further embodiment of the present invention, a laminate door is provided. The laminate door comprises a cement layer and a magnesium oxide layer. 
         [0019]    Alternatively, the laminate door further comprises a frame, wherein the frame is placed around the edge of the building board. 
         [0020]    Alternatively, the frame comprises metal, wood or plastics. 
         [0021]    In a further embodiment of the present invention, a laminate flooring is provided. The laminate flooring comprises cement layer and wooden layer. 
         [0022]    In a further embodiment of the present invention, a method for manufacturing the building board provided. The method comprises the steps of: providing a cement board and a magnesium oxide board; dehydrating the cement board and the magnesium oxide board; and binding the cement board and the magnesium oxide board. 
         [0023]    The building board of the present invention utilizes cement layer as the surface, which significantly improves its duration. The building board of the present invention has features of moisture proofing, mould and fungus proofing, erode proofing, fireproofing, soundproofing and free of deformation. Moreover, since the use of wood can be reduced, the building board of the present invention reduces the influence to the natural environment effectively. 
         [0024]    Furthermore, the use of magnesium oxide board further improves the performance of the building board. Compared with the conventional wooden building boards, the building board of the present invention has better flexibility, and easier to cut. 
         [0025]    These and other features of the present invention will be elucidated in the following embodiments of the present invention. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0026]    Features, objects and advantages of the present invention can be easily understood with the reference to detailed description of the non-limiting embodiments taken in conjunction with the accompanying drawings, in which: 
           [0027]      FIG. 1  illustrates a cross section view of a building board according to an embodiment of the present invention; 
           [0028]      FIG. 2  illustrates a cross section of a building board according to another embodiment of the present invention; 
           [0029]      FIG. 3  illustrates an overview of a laminate flooring according to a further embodiment of the present invention; 
           [0030]      FIG. 4  illustrates a laminate door according to a further embodiment of the present invention; 
           [0031]      FIG. 5  illustrates a flowchart of a method for manufacturing the building board according to an embodiment of the present invention; 
           [0032]      FIG. 6  illustrates a cross section of a laminate flooring according to a further embodiment of the present invention. 
       
    
    
     DETAILED DESCRIPTION OF EMBODIMENTS 
       [0033]    The embodiments of the present invention are discussed in details below with reference to the accompanying drawings. 
         [0034]      FIG. 1  illustrates a cross section view of a building board according to an embodiment of the present invention. The building board comprises a cement layer  102  and a magnesium oxide layer  104 . In practical applications, the building board can be used as laminate flooring, or laminate door of kitchen, cupboard and the like. 
         [0035]    When the building board is installed on the ground as laminate flooring, the magnesium oxide layer  104  is positioned close to the ground, for example, on a cement floor or brick floor, and the cement layer  102  is positioned away from the ground. Therefore, with reference to the ground, the building board comprises the cement layer  102  and the magnesium oxide layer  104  in a top-down order. In an embodiment, the cement layer  102  and the magnesium oxide  104  are bound together with glue. 
         [0036]    Compared with the wooden inner layer of the conventional wooden building boards, the magnesium oxide layer  104  of the building board of the present invention has better flexibility. The magnesium oxide layer  104  has features of nice moisture proofing, mould and fungus proofing, erode proofing, fireproofing, and free of deformation. Moreover, the magnesium oxide layer  104  also has the feature of soundproofing, and therefore the overall soundproof ability of the building board is improved. Thus, this building board is suitable for flooring pavement in storied buildings, or building doors such as kitchen door and the like. 
         [0037]    The cement layer  102  of the building board may comprise cement and glass fiber. The density of the cement layer  102  can be precisely controlled by adjusting the composition of the cement and glass fiber. In an embodiment, the cement layer  102  has a density of 1.1 to 1.8 g/cm 3 . Furthermore, since the cement layer  102  has a hard surface and is not easy to wear out, and it also has features of nice moisture proofing, mould and fungus proofing, erode proofing, fireproofing, and free of deformation, and therefore the building board of the present invention is more durable compared with conventional building boards using wooden material. 
         [0038]    In practical applications, the capability of moisture proofing and anti-deformation of the building board changes with the thickness of the cement layer  102  and the magnesium oxide layer  104 . In a specific embodiment, the cement layer  102  has a thickness from 2 to 20 millimeters. In another embodiment, the magnesium oxide layer 104 has a thickness from 8 to 15 millimeters. Such configuration in thickness ensures that the building board has perfect performance of anti-deformation and soundproofing. Moreover, since wood which is currently used with huge consumption has been substituted by the cement layer  102  and the magnesium oxide layer  104 , the building board of the present invention reduces the influence on the natural environment with cheaper manufacturing costs. 
         [0039]    Preferably, the building board of the present invention can further comprise a heating device. For example, the heating device is configured outside the magnesium oxide  104 . Since heat coming from the heating device can spread easily and fast through the magnesium oxide layer  104  and up into the room, and the magnesium oxide layer  104  can also keep warm longer, the magnesium oxide layer  104  is better for floor heating 
         [0040]      FIG. 2  illustrates a cross section view of a building board according to another embodiment of the present invention. The building board comprises a cement layer  202 , a magnesium oxide layer  204  and a buffer layer  206 , wherein the buffer layer  206  is connected to the magnesium oxide layer  204 . 
         [0041]    In an embodiment, the buffer layer  206  comprises plastics or rubber, therefore the laminate floor is elastic and comfortable for walking on. Moreover, the buffer layer  206  makes the magnesium oxide layer  204  of the building board perfectly fit to the installing surface, such as the ground, and therefore the soundproofing performance of the building board is significantly improved. 
         [0042]      FIG. 3  illustrates a top view of a laminate flooring according to a further embodiment of the present invention. As described in  FIG. 3 , the laminate flooring is shaped as regular hexagon. In other embodiments, the laminate flooring can also be shaped as square, rectangle, parallelogram, octagon and so on. 
         [0043]    In practical applications, different pieces of laminate flooring can joint together. In an embodiment, each side of the laminate flooring may have a connecting structure such as tongue or groove to joint to each other. In other embodiments, the laminate flooring can have click system to joint to each other, such as single click system or double click system. In a preferred embodiment, the surface of the laminate flooring is covered with a protective coating such as varnish or oil, which can ease the connection and provide further protection to the laminate flooring. In some embodiments, the oil used as the protective coating comprises natural oil or mineral oil. In practical applications, the oil coated on the surface of the laminate flooring may at least partially permeate into the surface of the laminate flooring and mix with the cement or other materials in the laminate flooring. The mixing of the oil and the cement flooring forms a specific surface, which is much stronger and more resistant to chemicals and physical scratches. 
         [0044]    It should be understood that the present invention is not limited to the connection manner between different pieces of the laminate flooring. 
         [0045]      FIG. 4  illustrates a laminate door according to a further embodiment of the present invention. The laminate door can be used as kitchen door, cupboard door and the like. The laminate door comprises the building board illustrated in  FIG. 1  or  2 . 
         [0046]    In  FIG. 4 , the laminate door further comprises a frame  408 , which is placed around the edge of the building board. Optionally, the frame  408  can comprise metal, wood or plastics. 
         [0047]    In some other examples, the building board depicted in  FIG. 1  may also be used for lampshades or housings for receiving lamps. The lampshades or housings may have openings for leaking light out. As the building board of the present invention has features of erode proofing, fireproofing and free of deformation, the lampshades or housings made of the building board is more durable. It should be understood that the previous embodiments for applying the building board of the present invention are merely illustrative and are not limited. 
         [0048]      FIG. 5  illustrates a flowchart of a method for manufacturing the building board according to an embodiment of the present invention. 
         [0049]    In step S 502 , provides a cement board and a magnesium oxide board. 
         [0050]    Specifically, the cement board can be made from cement and glass fibers mixed in a predetermined ratio. The magnesium oxide board can be made from magnesium oxide powder, glass fibers and/or wooden fibers mixed in a predetermined ratio. 
         [0051]    In step S 504 , dehydrates the cement board and the magnesium oxide board. 
         [0052]    Specifically, the cement board and the magnesium oxide board can be kept in a balance room, where the temperature and the humidity can be precisely controlled. In an embodiment, the magnesium oxide board and the cement board can be kept in the balance room for 2-3 weeks, so as to lower the water in the cement board and the magnesium oxide board down to 10-15% by mass. 
         [0053]    In step S 506 , binds the cement board and the magnesium oxide board. 
         [0054]    In an embodiment, step S 506  further comprises binding the cement board and the magnesium oxide board by cold pressing. The process time of the cold pressing is 6 to 10 hours, and the pressure is 5 kg/cm 2 . Optionally, the cement board and the magnesium oxide board can be bound with WBP (Water Boiled Proof) glue such as melamine glue and phenolic aldehyde glue. WBP glue has features of water proofing and water boiled proofing, which can effectively ensure the binding of the cement board and the magnesium oxide board. 
         [0055]    In an embodiment, after step S 506 , the method further comprises binding buffer material to the magnesium oxide board. That is, the buffer material adheres to the side of the magnesium oxide board far away from the cement board. Further, the buffer material can be bound to the magnesium oxide board with WBP glue. Optionally, the buffer material can be plastics or rubber. 
         [0056]    In an embodiment, after step S 506  or the step of binding buffer material, the method further comprises cutting the bound cement board and magnesium oxide board. Based on different applications, the building board can be separated as different sizes. 
         [0057]    In an embodiment, after the step of cutting the building board, the method further comprises forming a tongue or groove at each side of the building board, or forming a click system at each side of the building board. 
         [0058]    In an embodiment, after the step of cutting the building board, the method further comprises coating a protective coating over the cement board, such as oil, varnish or other comparable materials. Optionally, coloring materials can be added into the protective coating so as to improve the decorative effect of the building board. 
         [0059]      FIG. 6  illustrates a cross section of a laminate flooring according to a further embodiment of the present invention. As shown in  FIG. 6 , the laminate flooring comprises cement layer  602  and wooden layer  604 . When the laminate flooring is installed on the ground, the wooden layer  604  is positioned close to the ground, for example, on a cement floor or brick floor, and the cement layer  602  is positioned away from the ground. Therefore, with reference to the ground, the laminate flooring comprises the cement layer  602  and the wooden layer  604  in a top-down order. 
         [0060]    In an embodiment, the cement layer  602  and the wooden layer  604  are bound together with glue. Optionally, the cement layer  602  and the wooden layer  604  can be bounded with WBP (Water Boiled Proof) glue, such as melamine glue and phenolic aldehyde glue. The WBP glue has features of water proofing and water boiled proofing, which can ensure the binding of the cement layer  602  and the wooden layer  604 . 
         [0061]    The cement layer  602  of the laminate flooring may comprise cement and glass fibers. The density of the cement layer  602  can be precisely controlled by adjusting the composition of the cement and the glass fiber. In an embodiment, the cement layer  602  has a density of 1.1 to 1.8 g/cm 3 . Alternatively, the cement layer  602  has a thickness from 2 to 20 millimeters. The cement layer  602  features moisture proofing, mould and fungus proofing, erode proofing, fire proofing, and free of deformation. 
         [0062]    In an embodiment, the laminate flooring further comprises a butter layer which is connected to the wooden layer  604 . Specifically, the buffer layer is connected to one side of the wooden layer  604  far away from the cement layer  602 . The buffer layer comprises rubber or plastics materials, which has good elasticity, and therefore the laminate flooring has better performance on sound proofing. 
         [0063]    In an embodiment, the laminate flooring can be covered with protective coating, for example, oil or varnish, so as to protect the cement layer  602 . 
         [0064]    In an embodiment, the laminate flooring can be shaped as square, rectangle, parallelogram, hexagon, octagon and so on, and each side of the laminate flooring can have a connecting structure such as tongue or groove for the ease of connection. In another embodiment, the laminate flooring can use click systems to joint to each other, such as single click system or double click system. It should be understood that the present invention is not limited to the connection manner. 
         [0065]    Although the present invention has been described above in the accompanying drawings and detailed descriptions, it should be understood that such descriptions are merely illustrative and are not limited; the present invention is not limited to such embodiments. Those skilled in this art may understand and implement other variations from the disclosed embodiments by studying the specification, disclosed contents, accompanying drawings and appended claims.