GB2559805A - Improvements to a board - Google Patents
Improvements to a board Download PDFInfo
- Publication number
- GB2559805A GB2559805A GB1702760.8A GB201702760A GB2559805A GB 2559805 A GB2559805 A GB 2559805A GB 201702760 A GB201702760 A GB 201702760A GB 2559805 A GB2559805 A GB 2559805A
- Authority
- GB
- United Kingdom
- Prior art keywords
- board according
- layer
- plastics
- foam core
- weight
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Withdrawn
Links
- 229920003023 plastic Polymers 0.000 claims abstract description 62
- 239000004033 plastic Substances 0.000 claims abstract description 62
- 239000006260 foam Substances 0.000 claims abstract description 45
- 239000004005 microsphere Substances 0.000 claims abstract description 33
- 229920002635 polyurethane Polymers 0.000 claims abstract description 26
- 239000004814 polyurethane Substances 0.000 claims abstract description 26
- 239000000049 pigment Substances 0.000 claims abstract description 23
- 239000011521 glass Substances 0.000 claims abstract description 10
- 230000003115 biocidal effect Effects 0.000 claims abstract description 8
- 239000003063 flame retardant Substances 0.000 claims abstract description 7
- 239000000654 additive Substances 0.000 claims description 17
- 229920005862 polyol Polymers 0.000 claims description 15
- 150000003077 polyols Chemical class 0.000 claims description 15
- 239000012948 isocyanate Substances 0.000 claims description 13
- 150000002513 isocyanates Chemical class 0.000 claims description 11
- 230000000996 additive effect Effects 0.000 claims description 8
- 239000000945 filler Substances 0.000 claims description 6
- 239000000463 material Substances 0.000 claims description 6
- RNFJDJUURJAICM-UHFFFAOYSA-N 2,2,4,4,6,6-hexaphenoxy-1,3,5-triaza-2$l^{5},4$l^{5},6$l^{5}-triphosphacyclohexa-1,3,5-triene Chemical compound N=1P(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP=1(OC=1C=CC=CC=1)OC1=CC=CC=C1 RNFJDJUURJAICM-UHFFFAOYSA-N 0.000 claims description 5
- 239000002904 solvent Substances 0.000 claims description 4
- 230000002787 reinforcement Effects 0.000 claims description 3
- 239000000853 adhesive Substances 0.000 abstract description 4
- 230000001070 adhesive effect Effects 0.000 abstract description 4
- 229920001187 thermosetting polymer Polymers 0.000 abstract description 4
- 239000003973 paint Substances 0.000 description 9
- 239000002023 wood Substances 0.000 description 6
- 230000000704 physical effect Effects 0.000 description 5
- 230000015556 catabolic process Effects 0.000 description 4
- 238000000576 coating method Methods 0.000 description 4
- 150000001875 compounds Chemical class 0.000 description 4
- 238000006731 degradation reaction Methods 0.000 description 4
- 239000003365 glass fiber Substances 0.000 description 4
- 230000005855 radiation Effects 0.000 description 4
- 230000002195 synergetic effect Effects 0.000 description 4
- 241000233866 Fungi Species 0.000 description 3
- 239000011248 coating agent Substances 0.000 description 3
- 230000003247 decreasing effect Effects 0.000 description 3
- 230000000694 effects Effects 0.000 description 3
- 230000012010 growth Effects 0.000 description 3
- 239000004604 Blowing Agent Substances 0.000 description 2
- JOYRKODLDBILNP-UHFFFAOYSA-N Ethyl urethane Chemical compound CCOC(N)=O JOYRKODLDBILNP-UHFFFAOYSA-N 0.000 description 2
- 238000006243 chemical reaction Methods 0.000 description 2
- 239000000835 fiber Substances 0.000 description 2
- 125000002887 hydroxy group Chemical group [H]O* 0.000 description 2
- -1 isocyanate compounds Chemical class 0.000 description 2
- IQPQWNKOIGAROB-UHFFFAOYSA-N isocyanate group Chemical group [N-]=C=O IQPQWNKOIGAROB-UHFFFAOYSA-N 0.000 description 2
- 238000002955 isolation Methods 0.000 description 2
- 238000000034 method Methods 0.000 description 2
- 239000000203 mixture Substances 0.000 description 2
- JKQOBWVOAYFWKG-UHFFFAOYSA-N molybdenum trioxide Chemical compound O=[Mo](=O)=O JKQOBWVOAYFWKG-UHFFFAOYSA-N 0.000 description 2
- 238000007254 oxidation reaction Methods 0.000 description 2
- 239000011527 polyurethane coating Substances 0.000 description 2
- 238000002310 reflectometry Methods 0.000 description 2
- ACRQLFSHISNWRY-UHFFFAOYSA-N 1,2,3,4,5-pentabromo-6-phenoxybenzene Chemical compound BrC1=C(Br)C(Br)=C(Br)C(Br)=C1OC1=CC=CC=C1 ACRQLFSHISNWRY-UHFFFAOYSA-N 0.000 description 1
- JMTMSDXUXJISAY-UHFFFAOYSA-N 2H-benzotriazol-4-ol Chemical compound OC1=CC=CC2=C1N=NN2 JMTMSDXUXJISAY-UHFFFAOYSA-N 0.000 description 1
- 239000004254 Ammonium phosphate Substances 0.000 description 1
- OYPRJOBELJOOCE-UHFFFAOYSA-N Calcium Chemical compound [Ca] OYPRJOBELJOOCE-UHFFFAOYSA-N 0.000 description 1
- 206010061217 Infestation Diseases 0.000 description 1
- MXRIRQGCELJRSN-UHFFFAOYSA-N O.O.O.[Al] Chemical compound O.O.O.[Al] MXRIRQGCELJRSN-UHFFFAOYSA-N 0.000 description 1
- ABLZXFCXXLZCGV-UHFFFAOYSA-N Phosphorous acid Chemical class OP(O)=O ABLZXFCXXLZCGV-UHFFFAOYSA-N 0.000 description 1
- 239000004721 Polyphenylene oxide Substances 0.000 description 1
- 229920005830 Polyurethane Foam Polymers 0.000 description 1
- YSMRWXYRXBRSND-UHFFFAOYSA-N TOTP Chemical compound CC1=CC=CC=C1OP(=O)(OC=1C(=CC=CC=1)C)OC1=CC=CC=C1C YSMRWXYRXBRSND-UHFFFAOYSA-N 0.000 description 1
- 229910000148 ammonium phosphate Inorganic materials 0.000 description 1
- 235000019289 ammonium phosphates Nutrition 0.000 description 1
- 230000000843 anti-fungal effect Effects 0.000 description 1
- 230000000845 anti-microbial effect Effects 0.000 description 1
- 229910052788 barium Inorganic materials 0.000 description 1
- DSAJWYNOEDNPEQ-UHFFFAOYSA-N barium atom Chemical compound [Ba] DSAJWYNOEDNPEQ-UHFFFAOYSA-N 0.000 description 1
- 239000003139 biocide Substances 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 150000001638 boron Chemical class 0.000 description 1
- 239000004566 building material Substances 0.000 description 1
- 239000006227 byproduct Substances 0.000 description 1
- 229910052791 calcium Inorganic materials 0.000 description 1
- 239000011575 calcium Substances 0.000 description 1
- OZMJXAQDMVDWBK-UHFFFAOYSA-N carbamic acid;ethyl carbamate Chemical compound NC(O)=O.CCOC(N)=O OZMJXAQDMVDWBK-UHFFFAOYSA-N 0.000 description 1
- 150000004649 carbonic acid derivatives Chemical class 0.000 description 1
- 239000003054 catalyst Substances 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
- 238000004140 cleaning Methods 0.000 description 1
- MNNHAPBLZZVQHP-UHFFFAOYSA-N diammonium hydrogen phosphate Chemical compound [NH4+].[NH4+].OP([O-])([O-])=O MNNHAPBLZZVQHP-UHFFFAOYSA-N 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- NPZTUJOABDZTLV-UHFFFAOYSA-N hydroxybenzotriazole Substances O=C1C=CC=C2NNN=C12 NPZTUJOABDZTLV-UHFFFAOYSA-N 0.000 description 1
- 238000002329 infrared spectrum Methods 0.000 description 1
- 230000031700 light absorption Effects 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 230000005923 long-lasting effect Effects 0.000 description 1
- 238000012423 maintenance Methods 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 239000011159 matrix material Substances 0.000 description 1
- 230000000813 microbial effect Effects 0.000 description 1
- 230000003278 mimic effect Effects 0.000 description 1
- 238000000465 moulding Methods 0.000 description 1
- 238000013021 overheating Methods 0.000 description 1
- 229920000570 polyether Polymers 0.000 description 1
- 229920000642 polymer Polymers 0.000 description 1
- 229920003225 polyurethane elastomer Polymers 0.000 description 1
- 239000011496 polyurethane foam Substances 0.000 description 1
- 239000000047 product Substances 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 239000000376 reactant Substances 0.000 description 1
- 230000000717 retained effect Effects 0.000 description 1
- 239000004575 stone Substances 0.000 description 1
- 150000003467 sulfuric acid derivatives Chemical class 0.000 description 1
- 229920006352 transparent thermoplastic Polymers 0.000 description 1
- HQUQLFOMPYWACS-UHFFFAOYSA-N tris(2-chloroethyl) phosphate Chemical compound ClCCOP(=O)(OCCCl)OCCCl HQUQLFOMPYWACS-UHFFFAOYSA-N 0.000 description 1
Classifications
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
- E04C2/10—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products
- E04C2/20—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products of plastics
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
- F16L1/00—Laying or reclaiming pipes; Repairing or joining pipes on or under water
- F16L1/024—Laying or reclaiming pipes on land, e.g. above the ground
- F16L1/06—Accessories therefor, e.g. anchors
- F16L1/11—Accessories therefor, e.g. anchors for the detection or protection of pipes in the ground
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
- E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
- E04C2/284—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
- E04C2/292—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating composed of insulating material and sheet metal
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
- C09D5/00—Coating compositions, e.g. paints, varnishes or lacquers, characterised by their physical nature or the effects produced; Filling pastes
- C09D5/004—Reflecting paints; Signal paints
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/62—Insulation or other protection; Elements or use of specified material therefor
- E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
- E04B1/76—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only
- E04B1/78—Heat insulating elements
- E04B1/80—Heat insulating elements slab-shaped
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/62—Insulation or other protection; Elements or use of specified material therefor
- E04B1/92—Protection against other undesired influences or dangers
- E04B1/94—Protection against other undesired influences or dangers against fire
- E04B1/941—Building elements specially adapted therefor
- E04B1/942—Building elements specially adapted therefor slab-shaped
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F15/00—Flooring
- E04F15/02—Flooring or floor layers composed of a number of similar elements
Landscapes
- Engineering & Computer Science (AREA)
- Architecture (AREA)
- Structural Engineering (AREA)
- Civil Engineering (AREA)
- Physics & Mathematics (AREA)
- Electromagnetism (AREA)
- General Engineering & Computer Science (AREA)
- Life Sciences & Earth Sciences (AREA)
- Chemical & Material Sciences (AREA)
- Wood Science & Technology (AREA)
- Acoustics & Sound (AREA)
- Mechanical Engineering (AREA)
- Materials Engineering (AREA)
- Organic Chemistry (AREA)
- Laminated Bodies (AREA)
Abstract
The board 10 comprises a rigid plastics foam core 12 and one or more plastics layers 14 one of which includes microspheres for reflecting light. The microspheres may be glass. A plastics layer may include infrared reflective pigments. The foam core and plastics layers may be melded together, which means bonded via thermosetting and without any additional adhesive. The foam core acts as a support beam while the other layers are softer than the core. The core may be elastomeric polyurethane. The board may be textured and include fire retardant or biocidal properties.
Description
(71) Applicant(s):
The Millboard Company Limited
Unit A, Castle Court, Bodmin Road, Coventry,
Yorkshire, CV2 5DB, United Kingdom (56) Documents Cited:
CN 204590404 U CN 104652693 A (58) Field of Search:
INT CL E04B, E04C, E04F
Other: Online: WPI, EPODOC, PATENTS FULL TEXT (72) Inventor(s):
Steven John Thompson (74) Agent and/or Address for Service:
ip21 Ltd
Central Formalities Department, Lakeside 300, Old Chapel Way, Broadland Business Park, NORWICH, Norfolk, NR7 0WG, United Kingdom (54) Title of the Invention: Improvements to a board
Abstract Title: Board with foam layer and reflecting microspheres.
(57) The board 10 comprises a rigid plastics foam core 12 and one or more plastics layers 14 one of which includes microspheres for reflecting light. The microspheres may be glass. A plastics layer may include infrared reflective pigments. The foam core and plastics layers may be melded together, which means bonded via thermosetting and without any additional adhesive. The foam core acts as a support beam while the other layers are softer than the core. The core may be elastomeric polyurethane. The board may be textured and include fire retardant or biocidal properties.
1/1
\ ί\ϊ «Η CD δοοΰ χκκ^ ~ 1 , ΐ5
2S
Field of the Invention
The invention relates to boards. In particular, the invention relates to boards formed primarily from polymeric material.
Wood has been used as a building material for thousands of years, both for its ease of use and its structural attributes. However, in recent years, the limitations of wood - such as its cost, weight, need for treatment and its susceptibility to infestation and decay - have in a shift towards using alternative plastics materials. The applicant’s own prior application published as ΕΡΊ951971 has comprehensively addressed these issues and constitutes the closest prior art,
The invention provides a number of improvements to this art,
In a first broad independent aspect the invention provides a board comprising a rigid plastics foam core, and one or more plastics layers at least partially covering said rigid plastics foam core: said at least one plastics layer incorporating microspheres for reflecting light.
This is particularly advantageous because the plastics foam core creates the structural s support required whilst remaining lightweight, A foamed core also has decreased density which therefore requires less reactants to produce each board, and is therefore efficient to produce, in addition, the microspheres reflect light away from the board and reduce the amount of radiation that the board absorbs when left in direct sunlight. The temperature of a board left, in sunlight is directly proportional to the amount of radiation that said board absorbs and therefore, the rnicrospheres help to prevent the board from becoming hot when left In direct sunlight. Thus, ensuring the board is comfortable for the user to touch and optionally walk upon.
Preferably, the rnicrospheres comprise glass. This configuration is particularly advantageous due to its enhanced reflectivity when compared to plastics alternatives whilst lending itself to being efficiently melded into the plastics layer which acts as a support matrix for the glass rnicrospheres.
Preferably, at least one plastics layer comprises infrared reflective pigments. This is particularly advantageous because the Infrared pigments reflect light in the infrared spectrum, helping to prevent the board from absorbing radiation which would heat the board up. Furthermore, the rnicrospheres and the Infrared pigments work in a synergistic fashion, reflecting more light in combination then the sum total of their parts in isolation.
Preferably, the board further comprises an outermost layer comprising plastics material and pigment without any rnicrospheres, This Is particularly advantageous because additives such as rnicrospheres affect the consistency of a plastics layer and therefore dictate, to an extent, the physical properties of a plastics layer. By not including rnicrospheres, the outermost plastics layer is able to create the soft touch feel to the user that is preferable,
Preferably, the rigid plastics foam core and an adjacent plastics layer are melded together. This is particularly advantageous because it enables the layers to be physically attached to one another without the use of additional adhesives. This also facilitates a thermal setting process suitable for securing one layer to another in a mould.
Preferably, each adjacent layer is melded to an adjacent plastics layer. This provides an advantageously secure and therefore long lasting bond between adjacent layers.
Preferably, the foam core acts as a support beam whilst the or each layer is softer than said s core. This is particularly advantageous because the rigid foam core provides the structural support and the outer layers, which are softer, provide comfort for the user, which in one embodiment may be suitable for walking upon.
Preferably, the foam core incorporates fibres to provide structural reinforcement whilst 10 said at least one layer comprises no fibres. This is particularly advantageous because the fibres increase the structural rigidity of the board and enables the board to provide the same structural support with a decreased density, it also allows the outer layers to
Preferably, the foam core is a foamed polyurethane. In addition, the formation of the urethane linkage releases CO2 which helps to foam the core decreasing the volume of external blowing agent required.
Preferably, at least one layer comprises elastomeric polyurethane. This is particularly 20 advantageous since it allows the microspheres to be secured to the elastomeric polyurethane whilst allowing ft to retain sufficient elasticity to be soft to touch,
Preferably, the at least one layer incorporates coloured pigments.
Preferably, wherein at least one layer incorporates an additive with flame retardant properties. This is particularly advantageous because it reduces the fire hazard posed by traditional wood planking or plastic boards.
Preferably, the at least one layer incorporates an additive with biocidal properties. This is 30 particularly advantageous because it prevents the growth of moulds or fungus which in wet conditions can become slippery and potentially dangerous for any user walking across the boards,
Preferably, the at (east one layer is moulded to form a relief or pattern, This creates a natural feel to the board whilst achieving advantageous multidirectional reflectivity since the microspheres may be provided on all aspects or the formed relief.
s Optionally, the foam core comprises by weight of about 30 to about 45% of polyol.
Optionally., the foam core comprises by weight of about 20 to about 35% of isocyanate.
Optionally, the foam core comprises by weight of about 50 to about 70% of filler.
Optionally, the foam core comprises by weight of about 4 to about 10% of fibres. The fibres are optionally a form of filler.
Optionally, the outermost layer comprises by weight of about 60 to about 80% of polyol 15
Optionally, the outermost layer comprises by weight of about 8 to about 15% of isocyanate.
Optionally, the outermost layer comprises by weight of about 5 to about 20% of 20 pigments.
Optionally, the outermost layer comprises by weight of about 25 to about 50% of solvents.
Brief Descriptk
Figure 1 shows a board in cross sectional side view.
According to the present embodiment, the board comprises a rigid foamed plastics core with at a least one softer plastics coating on at least the upper surface of the foamed core,
In i oroferred embodiment, the hoard comprises a rigid foamed polyurethane core with a fi“st elastomentic polyurethane coating on at least the upper surface of the core and a second elastomeric polyurethane paint on at least the upper surface of the elastomeric coating.
s
The polyurethane core provides the structural rigidity to support the weight of the board, and in a preferred embodiment, support, the weight of one or more humans walking on the board.
to In one embodiment., the covering layers may he elastomeric layers. These may include the elastomeric polyurethane coating and the elastomeric polyurethane paint. These are softer than the core and therefore provide a cushioning effect for the user standing on the boards. In an alternative embodiment, the covering layers may be rigid polymeric layers.
ts In the elastomeric embodiment, the elastomeric coating or coatings include infrared pigments and glass microspheres which may be embedded therein. These features work in a synergistic way to reflect light and inhibit the absorption of light into the board. As a result, the boards can be placed in direct sunlight without becoming unpleasantly hot, making them ideal for outdoor decking or the like. This also allows the boards to have longer life cycles as they will be less prone to the effects of changes in temperature.
Polyurethane Is a polymer composed of organic units joined by carbamate (urethane) links.
Polyurethane foams and polyurethane elastomers are formed by reacting a polyol with an isocyanate, typically in the presence of a catalyst and other additives. The urethane linkage is produced by reacting an isocyanate group with a hydroxyl group on the polyol.
Preferably, the isocyanate comprises at least two Isocyanate functional groups per molecule and the polyol comprises at least two hydroxyl groups pier molecule. There are a wide variety of polyol and isocyanate compounds which can be used in the production of polyurethane. By altering the monomeric building blocks, the relative quantities of each, the reaction conditions and the type and quantity of additives included, it is possible to produce a polyurethane product with vastly different mechanical and physical properties.
It should be understood that all values of reaction compounds and conditions within this specification and claim set, are estimations prefixed by the term ‘about’, and therefore unless otherwise stated should be assumed to be approximations. Furthermore, the relative abundance of each component part is alterable to create the physical properties required for a given purpose and therefore the current invention should not be considered limited by the ranges provided. In further embodiments, the ranges specified may be exact limits should these need to he expressed without, the use of the term “about.
The term ‘melded' in the context of the current invention refers to the physical 10 attachment of distinct compounds during a thermosetting moulding process, without the use of adhesives.
To provide clarity, the components of the system which are common to different figures have retained identical numerical references throughout all figure descriptions,
Ϊ5
Figure 1 shows a first embodiment of a board 10 in cross sectional side view.
structural support of the board 10 is provided by the rigid plastics foam core 1.2. In a preferred embodiment, the foam core 12 is a rigid foamed polyurethane, in a further preferred embodiment, the foam core comprises by weight: from about 30% to about of polyol, from about 20% to about 35% of isocyanate, from about 50% to about 705 r, from about 0.1% to about 2% of blowing agent. The filler may be a fibre which i constitutes from about 4% to about 10% of the weight of the foam core.
Fillers may be selected from the following or a combination of the following; calcium, barium, carbonates, sulphates, glass fibre, aluminium trihydrate, phosphonate salts, boron salts.
in a preferred embodiment, the polyol may be a poly ether polyol.
In a preferred embodiment, the isocyanate is an aromatic isocyanate.
In a preferred embodiment, the fibre Is a glass fibre. In a further preferred embodiment, the glass fibre Is an E or S type glass fibre.
In the embodiment of Figure 1, a plastics layer 14 is melded to the foam core 12 at the boundary 13. Preferably, the plastics layer 14 has the physical properties of being softer than the foam core 12 and can provide a cushioning effect on any force that comes into contact with the plastics layer 14. In a preferred embodiment, the plastics layer 14 is an elastomeric plastic. In a further preferred embodiment, the plastics layer 14 is an elastomeric polyurethane.
The plastics layer 14, is preferably 1mm to 3mm thick and has additives to improve its physical properties. These additives are added to the liquid plastics and mixed to form a homogenous blend which is then thermoset. Microspheres may be added In one embodiment as the sole additive or in other embodiments as part of several other additives which together have a synergistic effect on certain properties of the board. Preferably, the microspheres range from 100 nanometres to 5 millimetres in diameter.
Further preferably, the microspheres range from 250pm to 3mm, Preferably the glass microspheres are located in the first 1 to 3 mm from the exposed surface of the board and constitute in volume between 5% and 25% of the layer's volume, in a preferred embodiment, the microspheres are glass microspheres. Preferably, the glass microspheres are virgin raw material, however, alternatively they could be from recycled sources.
Alternatively, the microspheres could be transparent thermoplastic or any other suitable material, in an embodiment, the microspheres are hollow, further reducing the weight of the board 10.
In the current embodiment, the reflective properties of the microspheres help reflect light radiation sway from the board 10. In a preferred embodiment, the microspheres have a reflective index of between 1.523 and 1.925. in a further preferred embodiment, the microspheres have s reflective index of 1,55. Light energy absorbed by the board 10 will be converted into heat energy to cause the board 10 to become hot. By reflecting light away from the board 10, the microspheres help to prevent the board from overheating, and to remain cool, to the touch. Furthermore, direct light can lead to oxidation reactions occurring within the board 10 which can lead to degradation, Therefore., by reflecting the light, the microspheres help to maintain the quality of the board and prevent degradation.
in addition to the microspheres, the plastics layer 14 includes infrared pigments, which reflect infrared (iR) light. As is the case with the microspheres, by reflecting light from the board 10, the iR pigments help to prevent the board 10 from heating up when left in direct sunlight, Furthermore, the combination of the microspheres and the IR pigments has a synergistic effect on the amount of light energy reflected by the boards 10, reflecting more light energy in combination then the combined total each additive would reflect in w isolation.
In a preferred embodiment, the elastomeric polyurethane layer Id would include one or more additives with flame retardant properties. These compounds could include but are not limited to; ammonium phosphate, molybdenum trioxide, pentabromodiphenyloxide, tricresyl phosphate, 2,3-dihromopropanoi or tri(2-chloroethyl) phosphate. Such compounds reduce the potential of a fire risk.
In a preferred embodiment, the elastomeric polyurethane layer 14 would include one or more additives with biocidal properties, including antimicrobial and antifungal properties.
This would protect the boards from microbial degradation and coverage with moulds and fungi. Moulds and fungi are common growths on traditional wooden or stone slates when left In the elements such as around a pool or patio area. One by product of such growths is that the boards or slabs become particularly slippery and dangerous to walk across, requiring regular cleaning or maintenance to prevent build up. The inclusion of one or
2$ more additives with biocidal properties within the elastomeric polyurethane layer 14 prevents the dangerous build-up of slimes and moulds that would otherwise be time consuming to remove.
In a preferred embodiment, the elastomeric polyurethane layer 14 comprises by weight;
from about 50% to about 60% of polyol, from about 4% to about 6% of isocyanate, from about 0.8% to about 1.2% of biocide, from about 30% to about 45% of flame retardant, from about 0.4% to about 2% of pigments.
In a preferred embodiment, the outer surface IS of the elastomeric polyurethane layer 14 would be ridged and troughed so as to produce a pattern or relief, as seen in figure Una further preferred embodiment, the relief on the surface 15 of the elastomeric polyurethane layer 14 would mimic wood grain, and provide a realistic wood look and feel &
in the embodiment of Figure 1, a plastics paint 16 is melded to the plastics layer 14 at the surface 15, In a preferred embodiment the combination of the layer 16 and layer 14 is of 1 millimetre to 4 millimetres, In a preferred embodiment, the plastics paint 16 is an elastomeric polyurethane paint. In a preferred embodiment, the elastomeric polyurethane paint has a composition by weight; from about 60% to about 80% of polyol, from about 5% to about 20% of pigments, from about 25% to about 50% of solvents, in a preferred embodiment, the plastics paint 16 contains pigments required to create an authentic look of wood planks. In an embodiment, a UV screener such as hydroxybenzotriazole is incorporated into the plastics paint 16 to help prevent oxidation reactions within the plastics paint 16 and the plastics layer 15, which would lead to degradation.
IS
1. A board comprising a rigid plastics foam core, and one or more plastics layers al least partially covering said rigid plastics foam core; said at least one plastics layer incorporating microspheres for reflecting light.
2. A board according to claim 1, wherein said microspheres comprise glass.
3. A board according to either claim 1 or claim 2, wherein said at least one plastics layer 10 comprises infrared reflective pigments,
4. A board according to any of the preceding claims, further comprising an outermost layer comprising plastics material and pigment without any microspheres.
is
5. A board according to any of the preceding claims, wherein said rigid plastics foam core and an adjacent plastics layer are melded together.
6, A board according to any of the preceding claims, wherein each adjacent layer is melded to an adjacent plastics layer.
7, A board according to any of the preceding claims, wherein said foam core acts as a support beam whilst the or each layer is softer than said core.
8, A board according to any of the preceding claims, wherein said foam core incorporates fibres to provide structural reinforcement whilst said at least one layer comprises no fibres,
9, A board according to any of the preceding claims, wherein said foam core is a foamed polyurethane.
10, A hoard according to any of the preceding claims, wherein at least, one layer comprises elastomeric polyurethane.
11, A board according to any of the preceding claims, wherein at least one layer incorporates coloured pigments.
‘12. A board according to any of the preceding claims., wherein at least one layer Incorporates an additive with flame retardant properties.
13. A board according to any of the preceding claims, wherein at least one layer incorporates an additive with biocidal properties,
14. A board according to any of the preceding claims, wherein at least one layer Is moulded to form a relief or pattern,
15. A board according to any of the preceding claims, wherein said foam core comprises by weight, of about 30 to about 45% of polyol.
16. A board according to any of the preceding claims, wherein said foam core comprises by weight of about 20 to about 35% of Isocyanate.
17. A board according to any of the preceding claims, wherein said foam core comprises by weight of about 50 to about 70% of filler.
18. A board according to any of the preceding claims, wherein said foam core comprises by weight of about 4 to about. 10% of fibres,
19. A board according to claim 4, wherein said outermost layer comprises by weight of about 60 to about 80% of polyol.
2Q. A board according to claim 4, wherein said outermost layer comprises by weight of about 8 to about 15% of isocyanate.
21, A board according to claim 4, wherein said outermost layer comprises by weight, of 30 about 5 to about 20% of pigments.
22. A board according to claim 4, wherein said outermost, layer comprises by weight of about 25 to about 50% of solvents.
Amendment to Claims have been filed as follows
Claims (20)
- Claims20 02 181. A board comprising a rigid plastics foam core, and one or more plastics layers at least partially covering said rigid plastics foam core; said at least one plastics layer incorporating5 microspheres for reflecting light, wherein said foam core is a foamed polyurethane and acts as a support beam whilst the or each layer is softer than said core.
- 2. A board according to claim 1, wherein said microspheres comprise glass.10
- 3. A board according to either claim 1 or claim 2, wherein said at least one plastics layer comprises infrared reflective pigments.
- 4. A board according to any of the preceding claims, further comprising an outermost layer comprising plastics material and pigment without any microspheres.
- 5. A board according to any of the preceding claims, wherein said rigid plastics foam core and an adjacent plastics layer are melded together.
- 6. A board according to any of the preceding claims, wherein each adjacent layer is melded 20 to an adjacent plastics layer.
- 7. A board according to any of the preceding claims, wherein said foam core incorporates fibres to provide structural reinforcement whilst said at least one layer comprises no fibres.25
- 8. A board according to any of the preceding claims, wherein at least one layer comprises elastomeric polyurethane.
- 9. A board according to any of the preceding claims, wherein at least one layer incorporates coloured pigments.
- 10. A board according to any of the preceding claims, wherein at least one layer incorporates an additive with flame retardant properties.20 02 18
- 11. A board according to any of the preceding claims, wherein at least one layer incorporates an additive with biocidal properties.
- 12. A board according to any of the preceding claims, wherein at least one layer is 5 moulded to form a relief or pattern.
- 13. A board according to any of the preceding claims, wherein said foam core comprises by weight of about 30 to about 45% of polyol.10
- 14. A board according to any of the preceding claims, wherein said foam core comprises by weight of about 20 to about 35% of isocyanate.
- 15. A board according to any of the preceding claims, wherein said foam core comprises by weight of about 50 to about 70% of filler.
- 16. A board according to any of the preceding claims, wherein said foam core comprises by weight of about 4 to about 10% of fibres.
- 17. A board according to claim 4, wherein said outermost layer comprises by weight of 20 about 60 to about 80% of polyol.
- 18. A board according to claim 4, wherein said outermost layer comprises by weight of about 8 to about 15% of isocyanate.25
- 19. A board according to claim 4, wherein said outermost layer comprises by weight of about 5 to about 20% of pigments.
- 20. A board according to claim 4, wherein said outermost layer comprises by weight of about 25 to about 50% of solvents.IntellectualPropertyOfficeApplication No: GB1702760.8 Examiner: Mr Kunal Saujani
Priority Applications (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
GB1702760.8A GB2559805A (en) | 2017-02-21 | 2017-02-21 | Improvements to a board |
PCT/GB2018/050439 WO2018154287A1 (en) | 2017-02-21 | 2018-02-20 | Improvements to a board |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
GB1702760.8A GB2559805A (en) | 2017-02-21 | 2017-02-21 | Improvements to a board |
Publications (2)
Publication Number | Publication Date |
---|---|
GB201702760D0 GB201702760D0 (en) | 2017-04-05 |
GB2559805A true GB2559805A (en) | 2018-08-22 |
Family
ID=58486971
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
GB1702760.8A Withdrawn GB2559805A (en) | 2017-02-21 | 2017-02-21 | Improvements to a board |
Country Status (2)
Country | Link |
---|---|
GB (1) | GB2559805A (en) |
WO (1) | WO2018154287A1 (en) |
Families Citing this family (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN113043704A (en) | 2021-04-16 | 2021-06-29 | 安徽森泰木塑集团股份有限公司 | Double-layer composite floor and preparation method thereof |
Citations (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN104652693A (en) * | 2013-11-21 | 2015-05-27 | 秦皇岛耀华新材料有限公司 | Nacreous composite reinforced plate |
CN204590404U (en) * | 2015-04-28 | 2015-08-26 | 四川省建筑科学研究院 | A kind of lightweight space enclosing structure of novel cooling and insulating |
Family Cites Families (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
AU695077B2 (en) * | 1993-09-08 | 1998-08-06 | Pq Holding, Inc. | Hollow borosilicate microspheres and method of making |
DE10102789A1 (en) * | 2001-01-22 | 2002-08-01 | Gerd Hugo | Coating with low solar absorption |
US7721496B2 (en) * | 2004-08-02 | 2010-05-25 | Tac Technologies, Llc | Composite decking material and methods associated with the same |
US20120073225A1 (en) * | 2005-11-24 | 2012-03-29 | James Edward Douglass | Planks and/or boards |
DE202011110443U1 (en) * | 2011-02-01 | 2014-01-29 | Eckstein Technology Ag | Coating material for insulating materials |
DE202014105390U1 (en) * | 2014-11-10 | 2015-02-26 | Mig Material Innovative Gesellschaft Mbh | Infrared (IR) reflecting compositions and infrared (IR) reflecting building materials |
-
2017
- 2017-02-21 GB GB1702760.8A patent/GB2559805A/en not_active Withdrawn
-
2018
- 2018-02-20 WO PCT/GB2018/050439 patent/WO2018154287A1/en active Application Filing
Patent Citations (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN104652693A (en) * | 2013-11-21 | 2015-05-27 | 秦皇岛耀华新材料有限公司 | Nacreous composite reinforced plate |
CN204590404U (en) * | 2015-04-28 | 2015-08-26 | 四川省建筑科学研究院 | A kind of lightweight space enclosing structure of novel cooling and insulating |
Also Published As
Publication number | Publication date |
---|---|
WO2018154287A1 (en) | 2018-08-30 |
GB201702760D0 (en) | 2017-04-05 |
Similar Documents
Publication | Publication Date | Title |
---|---|---|
CN107165376B (en) | A kind of plastic floor and its manufacturing method of super abrasive scratch resistance waterproof | |
JP7563548B2 (en) | Floor covering materials | |
US10174509B2 (en) | Flooring system including a material displaying dilatant properties, and methods for installation of an athletic flooring system | |
US5053274A (en) | Highly filled substantially solid polyurethane, urea and isocyannurate composites for indoor and outdoor applications, for load bearing, structural and decorative products | |
US20060130416A1 (en) | Flooring element | |
US20050281999A1 (en) | Structural and other composite materials and methods for making same | |
CN107108936A (en) | Cover plate and the method for manufacturing cover plate | |
US20240083156A1 (en) | Panel and method for manufacturing a panel | |
US20090308009A1 (en) | Composite Material Roofing Structure | |
KR20080092588A (en) | Wood flooring with composite core comprising kenaf and fiber board | |
GB2559805A (en) | Improvements to a board | |
JP6750243B2 (en) | Floor cosmetics | |
CN1969099A (en) | Fiber-reinforced composites and building structures comprising fiber-reinforced composites | |
KR101287255B1 (en) | Decorative Flooring Using Ramie Stem | |
US20230039750A1 (en) | Insulated Panel and Method of Manufacturing an Insulated Panel | |
US20230024890A1 (en) | Decorative Panel and Method of Manufacturing a Decorative Panel | |
CN113202254A (en) | Panel and method for manufacturing such a panel | |
KR102517836B1 (en) | Eco-friendly deck material utilizing composite comprising carbon compound and process for preparing the same | |
KR200287262Y1 (en) | Interior Block make use of waste-vinyl plastics | |
JP7003396B2 (en) | Floor decorative sheets and floor decorative materials | |
Grometto | Green-Housing | |
EA044192B1 (en) | INSULATED PANEL AND METHOD FOR MANUFACTURING INSULATED PANEL | |
EA045058B1 (en) | DECORATIVE PANEL AND METHOD FOR MANUFACTURING DECORATIVE PANEL | |
CZ2010658A3 (en) | Multilayer floor covering |
Legal Events
Date | Code | Title | Description |
---|---|---|---|
WAP | Application withdrawn, taken to be withdrawn or refused ** after publication under section 16(1) |