GB2549777A

GB2549777A - Composite constructional board

Info

Publication number: GB2549777A
Application number: GB1607464.3A
Authority: GB
Inventors: Frances Morris Angela
Original assignee: Wool Packaging Co Ltd
Current assignee: Wool Packaging Co Ltd
Priority date: 2016-04-29
Filing date: 2016-04-29
Publication date: 2017-11-01
Also published as: GB201607464D0

Abstract

Composite constructional board comprises outer sheets 3, 4 sandwiching needle-felted fibrous material 2. The outer sheets 3, 4 comprise corrugated cardboard attached to the fibres 2 by means of an adhesive. The corrugated card is preferably single sided (5, 6, figure 2) with corrugations (7, 8, figure 2) engaging fiber layer (2, figure 2) or double sided 3, 4, with smooth surface engaging fibre layer 2. The corrugated cards 3, 4 and fibrous batt 2 are supplied from rolls. The fibres 2 are preferably wool and cut to the same dimensions as the cards 3, 4. The sandwich laminate is used as thermal insulation, packaging carton.

Description

SOrndosite Constructional liBbard

This Invention relates to constructional boards of the type that are generally stiff and can be die-cut or otherwise machine-worked to form finished articles sooh as boxes, partitions and lightweight shelvesefc.

It is known from EF2727727 to provide a laminated sheet for forming into a generally rigid insulated package in which the sheet comprises a relatively stiff layer of Internally corrugated cardboard with a pliable liner of compressed hygroscopic fibre; strands such as wool on one lidi, that side of the packaging sheet being intended to provide thermal insulation on the inside of packaging; made with the; Sheet, sudh as a box, with the corrugated cardboard serving to provide a measure of external rigidity In order to provide mechanical support for the package and its codfents. This concept represents a development on earlier ferns of packaging in which the inner layer of insulation is separate fen the cardboard, such as by being contained in pillows for surrounding and Insulating an object being transported in the packaging.

The present invention is derived from the realisation that the foregoing concepts can be deyilpped further to provide a lightweight constructional board in which the layer of insulation is not exposed and whereby the constructional board Gan be used; with either side of the hoard feeing towards an object to be insulated without substantially compromising the insuiative properties of the board.

According to a first aspect of the invention there is provided a comppsite constructional bdard comprised Of first and second outer sheets of generally rigid: internally corrugated cardboard, between which sheets are sandwiched needle-felted fibre, such as wool, the first and second outer corrugated sheets beteg fofed to respective sides of the fibre by adhesive, thereby to form a generally rigid composite constructional board.

With this arrangement the composite board of the invention can be manufactured in standard spes? such as four feet wile and eight feet long, for subsequent sioFage, transport and use as if it were any other constructional board, which can thereafter be cut into any required Shape Oh site in which both sides of the board have equal rnechanrcat lirengih and surface regularity due to the use of intemaiiy Oonugated cardbo|rd sheete

Conveniently, the first and second outer sheets of corrugated cardboard are double sided, with the corrugations sandwiched between relatively smooth outer layers of paper or card. Alternatively^ tee first and second sheets of corrugated cardboard may be single sided; to provide a smooth outer layer ter each side of the constructional board, hut where the corrugations directly adhere to the needie-tepd fibre,

According to a second aspect of the invention there is provided a method of making a constructional board including the steps of, in any suitable order, cutting a iengte of cardboard and cutting a corresponding length ofneedle-felied fibre, thereafter securing the needle-felted fibre to the cut: length Of cate board:, cutting another length of cardboard to the same length and securing: it to the needle-felted fibre, SUOh as by means of a suitable adhesive, and thereafter compressing the composite board until a required thickness has been achieved.

According to a third aspect of the invention there is provided a method of making a constructional board including the steps of providing a bait of needle-felted fibre on a roll, providing first and second rolls of single-sided corrugated cardboard, one for each side of lie fibre, and securing the cardboard to each respective side gl the fibre, such as by adhesive, with the corrugations facing towards the fibre and thereafter cutting discrete lengths to form composite boards.

According to a fourth aspect: of the indention there is provided a method of forming a composite constructional board comprised Of double-sided corrugated cardboard on respectively opposite sides between which is sandwiched a layer of needle-felted fibre, the method including the steps of providing first and second roils of single-sided cormgated cardboard in which the corrugations are transverse to the direction of roil which corrugations face each Other when unrolled, providing a pair Of roils of paper one for each mil of corrugated cardboard and fixing the paper to the unrolled corrugations, such as by adhesive, fo form double-sided corrugated cardboard, and providing a roll of needle-felted fibre and securing lit between the double-sided sheets of cardboard, whereby to form a continuous length of composite sheet and thereafter cutting the sheet to required lengths to form constructional boards,

The: invention wifi now be described, by way of example only, with reference to the Accompanying drawings in which:

Figure 1 is a cross-section of part of a constructional board: using doublesided ftoiugatod cardboard, and

Figure 2 is a part sectional view of a constructional board using single-sided corrugated cardboard. inferring firstly to Figure 1, there is shown part of a constructional board 1 comprised of an inner layer or baft of needle-felted fibre 2 * such as wool, sandwiched between respectively opposite sheets of double-sided corrugated cardboard 3, 4 and retained in that position by any suitable meads, lush as an orgaric adhesive. The board 1 is typically compressed to provide a standard thickness, such as by fie use of a press or rollers, and is cut to any suitable length, whereafter it Can he cut into any required shape to form eg die-cut templates for forming a thermally-insulated carton or compartment within ah essentially untbsulsfod container. The generally rigid nature of the board 1 means that it is elslly transportable and can be Stored either fiat or on Its edge until required for usee This contrasts with the need, otherwise, to manufacture the end-user product, such m a carton, which would otherwise hme id be manufactured off-site arid transported to where it is required, thereby increasing the cost and oomplei^y # the exercise which is notconduclveio small or even single-scale production where e.g. cartons of a particular shape or size are required

Figure 2: shows an alternative arrangement in Which foe bat of needle-felted fibre 2 is sandwiched bel®een respectively opposite layers 5, 8 of single-sided coratgated cardboard in which the corrugations 7, 8 are directly fixed to the fibre 2 with a suitable adhesive.

This arrangement is particularly suitable for continuous production from rails cf sihgle-sfoed corrugifod where foe corrugato^ to the direction of rail and a suitable adhesive can be easily applied to eaehside of the fibre batt i and/or the corrugations 7, 8 to form a continuous sheet which is then cut Into required lengths of constructional board, preferably after feeing compressed to a required thickness, This method of assembly can also be used with reference to the hoard shown in Figure 1 hut only If the double-sided cardboard 4 is effectively constructed during the process in which the corrugations 7, 8 of Figure 2 are covered with respective layers of paper to form double-sided cardboard before they are adhered to and compressed against the fibre hatt 2.

Whether the constructional board is made from single or double sided sheets of corrugated cardboard It will, nevertheless, be apparent that the board is easily transportable and stored for use or partial use as required, in much the same way as any other constructional board.

Claims

1. A composite constructional board comprised of first and second outer sheets of generally rigid internally corrugated cardboard, between which sheets aid: sandwiched needle-felted fibre, such as wool, the first and second outer corrugated sheets being toi:tespe£^ivevsiids$::0f the fibre by adhesive, whereby te term a generally rigid composite constructional board.

2,. A board according to claim 1 wherein the first and second outer sheets of corrugated cardboard are double sided., wih the corrugations sandwiched between relatively smooth outer layers of psper or card.

3. A board according to claim 1 wherein the first and second sheets of corrugated cardboard ate single sided to provide a smooth outer layer for each side of the constructional hoard, where the corrugations directly adhere to the needle-felted fibre,

4. A method of making a constructional board including the Steps if, In any sditabte order, -#uiih| a length of cardboard and outing a corresponding length of needle-felted fibre, thereafter securing the needle-felted fibre to the cut length of cardboard, outing another length of cardboard to the same length and securing it to the needle-felted fibre, such as hy means of a suitable adhesive, and thereafter compressing the composite board until a required thickness has been achieved.

5. A method of making a constructional board including the steps of providings a ballot needle-felted fibre on a roil, providing first; and: second: rolls Of single-sided corrugated cardboard, one for each side of the fibre, and securing the cardboard to each respective side of the fibre, such as by adhesive, with the corrugations facing towards file fibre and thereafter cutting discrete lengths to form composite boards.

6. A method of forming a composite constructional board comprised of double-sided corrugated cardboard on respectively opposite sides between which is sandwiched a layer of needle-felted fibre, the method including the steps of providing first and second rolls of single-sided corrugated cardboard in which the corrugations are transverse to the direction of roll which corrugations face each other- when unrolled, providing a pair of roils of paper one for each roll of corrugated cardboard and fixing the paper to the unrolled corrugations, such as by adhesive, to form double-sided corrugated cardboard, and providing a roil of needle-felted fibre and securing it between the doubte-sided sheets of cardboard, whereby to form a continuous length of composite sheet and thereafter culling the sheet to required lengths to form constructional boards,

7. A board substantially as hereinbefore described with reference to Figure 1 or Figure 2. 8 A method of making a board substantially as hereinbefore described with reference to Figure 1 or Figure 2.