Composite panel and method of making the same

Details Composite panel and method of making the same Composite panel and method of making the same

1999-04-13

2001-03-06

Yao, Sam Chuan (Department: 1733)

Adhesive bonding and miscellaneous chemical manufacture

Methods

Surface bonding and/or assembly therefor

C156S179000, C264S113000

Reexamination Certificate

active

06197142

ABSTRACT:

FIELD OF THE INVENTION
The present invention relates to a composite panel and a method of making the same.
BACKGROUND OF THE INVENTION
While composite panels are typically made out of wood fibre, they can be made out of other materials such as straw. Composite panels made out of wood fibre are known by a variety of names, including: oriented strandboard, wafer board, and chip board. In the past, structural reinforcement of these composite panels has been achieved by selection of the shape of the panel. For example, some success has been obtained through the use of a sinusoidal form, commonly known as “wave board”. U.S. Pat. No. 3,083,128 and U.S. Pat. No. 4,904,517 disclose structural reinforcement through a plurality of external reinforcing ribs.
Unfortunately, the same features of shape or configuration that provide composite panels with their structural reinforcement, have inherent disadvantages that have retarded their commercial acceptance. The panels are difficult to manufacture, as special press platens are required to create the special shapes. The special press platens are difficult to adapt to high speed, high volume production runs. Consequently, the composite panels have tended to be expensive. In use, the special shapes make the composite panels difficult to consistently cut to a desired size and, generally, make them more difficult to work with.
SUMMARY OF THE INVENTION
What is required is a structurally reinforced composite panel that derives its structural reinforcement from other than its shape.
According to one aspect of the present invention there is provided a composite panel which includes fibres adhered together by means of an adhesive binder to form a sheet having opposed planar faces. Fibre reinforcement ribs are imbedded in the sheet.
The composite panel constructed in accordance with the teachings of the present invention has planar faces. This enables it to be manufactured with only minor changes to the forming lines of existing plants. The resulting composite panels can be used for virtually any application. The structural reinforcement is embedded in the wood panel in the form of reinforcement ribs. The reinforcement ribs can take a number of forms. For example, the reinforcement ribs can be parallel and spaced at intervals along the sheet or can be serpentine.
According to another aspect of the present invention there is provided a method of making a composite panel. A first step involves laying a continuous layer of fibres mixed with an adhesive binder. A second step involves laying onto the layer of fibres, reinforcement ribs of fibres mixed with an adhesive binder. A third step involves pressing the layer of fibres and the reinforcement ribs together to form a panel with planar opposed faces and reinforcement ribs imbedded in the panel.


REFERENCES:
patent: 3083128 (1963-03-01), Herrington et al.
patent: 3884749 (1975-05-01), Pankoke
patent: 4061813 (1977-12-01), Geimer et al.
patent: 4904517 (1990-02-01), Lau et al.

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