CA2924333C - Composite structural component and method of making same - Google Patents
Composite structural component and method of making same Download PDFInfo
- Publication number
- CA2924333C CA2924333C CA2924333A CA2924333A CA2924333C CA 2924333 C CA2924333 C CA 2924333C CA 2924333 A CA2924333 A CA 2924333A CA 2924333 A CA2924333 A CA 2924333A CA 2924333 C CA2924333 C CA 2924333C
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- layer
- pair
- bonded
- corrugated
- layers
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form
- B32B3/02—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by features of form at particular places, e.g. in edge regions
- B32B3/08—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by features of form at particular places, e.g. in edge regions characterised by added members at particular parts
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B27/10—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of paper or cardboard
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B29/00—Layered products comprising a layer of paper or cardboard
- B32B29/002—Layered products comprising a layer of paper or cardboard as the main or only constituent of a layer, which is next to another layer of the same or of a different material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B29/00—Layered products comprising a layer of paper or cardboard
- B32B29/08—Corrugated paper or cardboard
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form
- B32B3/10—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material
- B32B3/12—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material characterised by a layer of regularly- arranged cells, e.g. a honeycomb structure
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form
- B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
- B32B3/28—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by a layer comprising a deformed thin sheet, i.e. the layer having its entire thickness deformed out of the plane, e.g. corrugated, crumpled
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
- B32B7/04—Interconnection of layers
- B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C63/00—Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor
- B29C63/0026—Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor an edge face with strip material, e.g. a panel edge
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2250/00—Layers arrangement
- B32B2250/05—5 or more layers
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2250/00—Layers arrangement
- B32B2250/40—Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
- B32B2260/02—Composition of the impregnated, bonded or embedded layer
- B32B2260/028—Paper layer
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
- B32B2260/04—Impregnation, embedding, or binder material
- B32B2260/046—Synthetic resin
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/40—Properties of the layers or laminate having particular optical properties
- B32B2307/408—Matt, dull surface
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/50—Properties of the layers or laminate having particular mechanical properties
- B32B2307/58—Cuttability
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/70—Other properties
- B32B2307/732—Dimensional properties
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
- B32B37/02—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by a sequence of laminating steps, e.g. by adding new layers at consecutive laminating stations
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
- B32B37/12—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives
- B32B37/1284—Application of adhesive
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
- B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
- B32B37/146—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers whereby one or more of the layers is a honeycomb structure
Abstract
ABSTRACT
A composite includes a board. The board includes: a pair of corrugated layers, each corrugated layer being formed from two corrugated sheets bonded together; and a cardboard honeycomb layer disposed between and bonded to the corrugated layers, the honeycomb layer being orientated such that the cells extend between the corrugated layers. The board can be cut using conventional machinery without fraying , thereby requiring little or no sanding, and can be edgetaped without being crushed using conventional edge taping machinery.
Date Recue/Date Received 2022-04-20
A composite includes a board. The board includes: a pair of corrugated layers, each corrugated layer being formed from two corrugated sheets bonded together; and a cardboard honeycomb layer disposed between and bonded to the corrugated layers, the honeycomb layer being orientated such that the cells extend between the corrugated layers. The board can be cut using conventional machinery without fraying , thereby requiring little or no sanding, and can be edgetaped without being crushed using conventional edge taping machinery.
Date Recue/Date Received 2022-04-20
Description
COMPOSITE STRUCTURAL COMPONENT
AND METHOD OF MAKING SAME
TECHNICAL FIELD
[0001] The present disclosure relates generally to a composite structural component.
BACKGROUND
AND METHOD OF MAKING SAME
TECHNICAL FIELD
[0001] The present disclosure relates generally to a composite structural component.
BACKGROUND
[0002] Composite structural components including composite boards utilizing honeycomb centers have been disclosed in the art, However, known composite boards suffer from an unattractive combination of: (i) relatively high processing costs; and (ii) relative difficulty in machining and/or edge banding it.
BRIEF DESCRIPTION OF THE DRAWINGS
BRIEF DESCRIPTION OF THE DRAWINGS
[0003] FIG. 1 is a top perspective view of a finished composite component according to one exemplary embodiment of the invention; and
[0004] FIG. 2 is a view along 2-2 of FIG. 1.
DETAILED DESCRIPTION
DETAILED DESCRIPTION
[0005] A composite component 20 which forms an exemplary embodiment of the present invention is hereinafter described with reference to FIGS. 1 and 2.
[0006] Composite component 20 will be seen to include a composite board 10 and a PVC edge band 11.
[0007] Composite board 10 includes a honeycomb layer 12, a pair of corrugated layers 14 flanking the honeycomb layer 12, a backer layer 16 overlying each corrugated layer and a cover layer 18 overlying each backer layer 16.
[0008] Honeycomb layer 12 shown is formed from 0.5" honeycomb sheet from Axxon Packaging.
[0009] Each corrugated layer 14 is formed from two EB corrugated sheets bonded together and to the honeycomb layer with PVA glue. [For greater certainty, layer 20 is an E flute layer with a thickness of approximately 0.06" and layer 22 is a B
flute layer with a thickness of approximately 0.111
flute layer with a thickness of approximately 0.111
[0010] Each backer layer 16 is formed from PolybakTM B90, with a thickness of .026", and is bonded to the adjacent corrugated layer 14 with PVA glue.
[0011] Each cover layer 18 is a matte RenolitTM vinyl with a thickness of 0.008"
bonded to the corrugated layer with PVA glue.
bonded to the corrugated layer with PVA glue.
[0012] The method of making composite board 10 is described as follows:
= an EB sheet is put through a glue roller applicator to apply a layer of adhesive to produce a coated EB sheet and a further EB sheet is laid upon the coated EB sheet to form an EBBE combination;
= the EBBE combination is passed through a pinch roller to form an EBBE
sheet;
= the honeycomb sheet is passed through a double roll glue applicator to apply adhesive on both sides of the honeycomb sheet and is laid upon an EBBE
sheet, and a further EBBE is laid upon both, to form an EBBE-honeycomb-EBBE bundle;
= the EBBE bundle is passed through a pinch roller to produce an EBBE
sandwich and the EBBE sandwich is placed in a pneumatic pressure for 20 minutes to produce an EBBE board;
= the backer and cover layers are applied in a manner analogous to the manner of application of the EBBE layers; and = the entire assembly is machined to size using a HomagTM WIKI Vantage 43 CNC cutting machine armed with the Solid Carbide UN-ruffer 67-445 (1/2"
Date Recue/Date Received 2022-04-20 dia) and the Solid Carbide Honeycomb Hogger.
= an EB sheet is put through a glue roller applicator to apply a layer of adhesive to produce a coated EB sheet and a further EB sheet is laid upon the coated EB sheet to form an EBBE combination;
= the EBBE combination is passed through a pinch roller to form an EBBE
sheet;
= the honeycomb sheet is passed through a double roll glue applicator to apply adhesive on both sides of the honeycomb sheet and is laid upon an EBBE
sheet, and a further EBBE is laid upon both, to form an EBBE-honeycomb-EBBE bundle;
= the EBBE bundle is passed through a pinch roller to produce an EBBE
sandwich and the EBBE sandwich is placed in a pneumatic pressure for 20 minutes to produce an EBBE board;
= the backer and cover layers are applied in a manner analogous to the manner of application of the EBBE layers; and = the entire assembly is machined to size using a HomagTM WIKI Vantage 43 CNC cutting machine armed with the Solid Carbide UN-ruffer 67-445 (1/2"
Date Recue/Date Received 2022-04-20 dia) and the Solid Carbide Honeycomb Hogger.
[0013] Edge band 11 is applied using a HomagTM Edgebander and PURTM glue to form the composite component 20.
[0014] Whereas a specific embodiment is herein shown and described, variations are possible. For example:
= whereas a specific cutter is mentioned, other cutters, such as table saws, band saws and CNC routers can be utilized;
= whereas EBBE sheets are mentioned, other combinations can be utilized, provided that the thickness of each corrugated layer is at least about 3/8", which allows for edge banding;
= whereas a honeycomb layer of 0.5" is mentioned, thicknesses of up to 2.25"
can be utilized;
= whereas a PVC edge band is specifically mentioned, ABS and polypropylene can also be used;
= whereas PUR glue is taught for use in edge banding, hot-melt EVA can also be utilized;
= whereas a pair of cover layers is shown, these are not essential;
= whereas PolyBakTM is specifically mentioned, other strong polymer saturated Kraft papers can be used without sacrificing machinabilit; and = whereas RenolitTM vinyl is mentioned, other standard general purpose laminates can be used.
Date Recue/Date Received 2022-04-20
= whereas a specific cutter is mentioned, other cutters, such as table saws, band saws and CNC routers can be utilized;
= whereas EBBE sheets are mentioned, other combinations can be utilized, provided that the thickness of each corrugated layer is at least about 3/8", which allows for edge banding;
= whereas a honeycomb layer of 0.5" is mentioned, thicknesses of up to 2.25"
can be utilized;
= whereas a PVC edge band is specifically mentioned, ABS and polypropylene can also be used;
= whereas PUR glue is taught for use in edge banding, hot-melt EVA can also be utilized;
= whereas a pair of cover layers is shown, these are not essential;
= whereas PolyBakTM is specifically mentioned, other strong polymer saturated Kraft papers can be used without sacrificing machinabilit; and = whereas RenolitTM vinyl is mentioned, other standard general purpose laminates can be used.
Date Recue/Date Received 2022-04-20
[0015] Further, whereas HelmibondTM 816 is mentioned, other glues can be used.
Advantages of using PUR glue, for example, are that it sets quickly and can avoid or minimize the need for pressing. However, it is important to select a glue that hardens and strengthens the surface. HelmibondTM 816 was found to provide a hard glass-like surface upon curing, which provided a board that did not require special handling, that cut using conventional machinery without fraying [thereby requiring little or no sanding]
and that could be edgetaped without being crushed using conventional edge taping machinery.
Date Recue/Date Received 2022-04-20
Advantages of using PUR glue, for example, are that it sets quickly and can avoid or minimize the need for pressing. However, it is important to select a glue that hardens and strengthens the surface. HelmibondTM 816 was found to provide a hard glass-like surface upon curing, which provided a board that did not require special handling, that cut using conventional machinery without fraying [thereby requiring little or no sanding]
and that could be edgetaped without being crushed using conventional edge taping machinery.
Date Recue/Date Received 2022-04-20
Claims (11)
1. A composite comprising:
a board including a pair of corrugated layers, each of the pair of corrugated layers being formed from two corrugated sheets bonded together;
a cardboard honeycomb layer disposed between and bonded to the pair of corrugated layers, the honeycomb layer being orientated such that the cells extend between the pair of corrugated layers.
a board including a pair of corrugated layers, each of the pair of corrugated layers being formed from two corrugated sheets bonded together;
a cardboard honeycomb layer disposed between and bonded to the pair of corrugated layers, the honeycomb layer being orientated such that the cells extend between the pair of corrugated layers.
2. The composite according to claim 1, wherein the pair of corrugated layers are bonded to the honeycomb layer by PVA glue.
3. The composite according to claim 1, wherein each of the pair of corrugated layers comprises a pair of B flute layers bonded together and a pair of E
flute layers each bonded to one of the B flute layers.
flute layers each bonded to one of the B flute layers.
4. The composite according to claim 3, wherein the E and B flute layers are bonded together with PVA glue.
5. The composite according to claim 3, wherein the E flute layer has a thickness of approximately 0.06" and the B flute layer has a thickness of approximately 0.11".
6. The composite according to claim 3, wherein the board further comprises, for each of the pair of corrugated layers, a backer layer overlying and bonded to said each of the pair of corrugated layers.
7. The composite according to claim 6, wherein each backer layer is formed from Polybak B90, with a thickness of .026", and is bonded to the adjacent corrugated layer with PVA glue.
Date Recue/Date Received 2022-1 0-1 9
Date Recue/Date Received 2022-1 0-1 9
8. The composite according to claim 6, wherein the board further comprises, for each backer layer, a cover layer overlying and bonded to said each backer layer.
9. The composite according to claim 8, wherein the cover layer is a matte Renolit vinyl with a thickness of 0.008" bonded to said each backer layer with PVA glue.
10. The composite according to claim 2, further comprising an edge band surrounding the edge of the board.
11. The composite according to claim 10, wherein the edge band is PVC and is bonded to the board using PUR glue.
Date Recue/Date Received 2022-10-19
Date Recue/Date Received 2022-10-19
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA2924333A CA2924333C (en) | 2016-03-21 | 2016-03-21 | Composite structural component and method of making same |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA2924333A CA2924333C (en) | 2016-03-21 | 2016-03-21 | Composite structural component and method of making same |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CA2924333A1 CA2924333A1 (en) | 2017-09-21 |
| CA2924333C true CA2924333C (en) | 2023-10-03 |
Family
ID=59895530
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA2924333A Active CA2924333C (en) | 2016-03-21 | 2016-03-21 | Composite structural component and method of making same |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA2924333C (en) |
-
2016
- 2016-03-21 CA CA2924333A patent/CA2924333C/en active Active
Also Published As
| Publication number | Publication date |
|---|---|
| CA2924333A1 (en) | 2017-09-21 |
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