GB2609231A

GB2609231A - Reinforcing element

Info

Publication number: GB2609231A
Application number: GB2110664.6A
Authority: GB
Inventors: Baker Trevor
Original assignee: Individual
Current assignee: Individual
Priority date: 2021-07-24
Filing date: 2021-07-24
Publication date: 2023-02-01
Also published as: GB202110664D0

Abstract

A reinforcing element comprising a laminate comprising a layer of a solid surface material 7, 8 and a layer of fibreglass 9. The element may be used to reinforce the seams or joins 1 in support boards or panels 2, 3, for instance, doors, worktops or countertops. The preferred solid surface comprises an acrylic, epoxy or polyester resin or aluminium hydroxide, especially 35-45 wt.% methyl methacrylate and 45-55 wt.% aluminium trihydrate (ATH). Also disclosed is a method of reinforcing a support board or panel comprising securing to the support board or panel such a reinforcing element.

Description

Reinforcing Element This invention pertains generally to the field of reinforcing elements and particularly, but not exclusively, to reinforcing elements for support boards or panels, for instance, those serving as countertops or worldops.

Solid surface materials (SSMs) are man-made materials typically composed of a combination of alumina trihydratc (ATH), acrylic, polyester resins or epoxy and various pigments to provide a wide variety of colour and designs. They provide a solid surface that is non-porous, and low maintenance. An acrylic resin such as polymethylmethacrylate is typically present in the range of 35 -45% by weight and that of aluminium trihydrate 55 -45% by weight. There may be present small amounts of a pigment (less than 1% by weight) and additives (less than 1% by weight). They are typically manufactured in sheet form, and frequently fabricated to form seamless countertop installations, where they can mimic the appearance of naturally occurring materials such as granite, marble or stone, and any joints in the material are near enough invisible.

SSMs may be manufactured by mixing acrylic, epoxide or polyester resin with powdered bauxite filler and pigments. The material chemically cures and is heated to 60 °C or more. Cured material is then cut in sheets or shapes and sanded on one or both sides.

Sometimes the material is brought to 160 °C and cooled, to improve its heat resistance.

SSMs are readily worked and are suitable for thermoforming. They may be provided in the form of flat sheets with different thicknesses and having various appearances and colours. They have high densities, high strength and are highly resistant to fire and liquid penetration. They can also be cast into a variety of shapes to form sinks, shower trays and bathtubs. Alternatively, they can be heated and bent into three-dimensional shapes through thennofonning processes. This makes SSMs extremely versatile.

A countertop fabricator would typically join sheets of solid surface material into desired shapes using a two-part adhesive. Once cured, the joint can be machined flat to provide a seamless finish. An advantage to using SSMs is it's impermeability. A sink can be formed within a worktop without any gaps or crevasses along the join. This eliminates issues of water, bacteria dirt and other detritus from becoming lodged in a gap. A worktop can also be provided with an integral backsplash that seamlessly follows wall contours, again leaving no gaps where particles can collect. This makes keeping a surface dean and free from bacteria far easier.

SSMs offer a low maintenance solution. Should the material become scratched, or damaged in anyway, most of this damage is relatively straightforward to repair. Since the surface is solid throughout, any surface wear and tear can typically be polished out. SSMs also offer a wide variety of surface finishes, from matt to satin, to high gloss.

There are potentially many applications for countertops which are hygienic, seamless and not porous but weight and strength concerns prohibit or restrict the use of SSMs. Traditionally, 12mm cleats are used to reinforce seams in the production of 12inm seamless countertops. While these cleats strengthen the material and prevent seam failure, the combined thickness of cleat and countertop, and therefore the overall minimum thickness is 24mm, which is too thick for many installations. The number of joins and location of these joins has an impact on the thickness of surface that can be used for a particular application. SSMs can also be similar in cost to natural material alternatives, Nvhich therefore fails to make them a cost-effective option.

Existing SSMs do not typically offer sufficient impact, compression and shear stress capabilities of the surface to be used for all applications. SSMs could be more widely used in commercial environments such as for use as wall panelling in airports and hotels, or within wet rooms and showers. However, the current requirement to use the SSM for the entire panel or section, makes the cost considerably high, and therefore in most cases it does not prove to be a cost-effective option.

The prior art shows a number of materials which attempt to address these needs in various ways.

W02006000320 discloses a prefabricated wall system for constructing environments with a high degree of sterility, such as operating theatres. The wall system includes at least one self-supporting panel comprising a first sheet of SSM where the panel comprises a metal sheet that is spot fixed to the SSM. Whilst providing a substantially sterile surface for such a clean environment, it requires a layer of metal as reinforcement, and therefore the unit cost for such a wall system is high.

Whilst the prior art appears to address the issue of reinforcing SSMs to ensure their suitability for all conditions and environments, thus allowing for structural panels of considerable sizes to be created, they do not appear to offer a cost-effective reinforcement means. Whilst the prior art shows cleats being used to reinforce joints, these currently increase the overall thickness of the surface, making the composite too thick for a wide range of purposes.

Preferred embodiments of the present invention aim to provide a composite surface with sufficient reinforcing means, particularly along joints, to allow for structural panels of a considerable size to be created. A further embodiment of the present invention aims to provide a reinforcement means for a support board or panel, that does not greatly increase the thickness of the panel.

According to the present invention, there is provided a reinforcing element comprising a laminate comprising a layer of a solid surface material and a layer of fibreglass.

The present invention also provides a support board or panel having a reinforcing element of the invention.

The support board or panel may be, for instance, a countertop or worktop.

It has surprisingly been discovered that a combination of a layer of an SSM secured to a layer of fibreglass provides a particularly effective reinforcing element for use in strengthening and maintaining structures such as support boards or panels.

The reinforcing sheet may be applied across part of or the entirety of the support board or panel.

The reinforcing sheet may be used in a variety of applications in addition to worktops, an example being as reinforcements for doors.

Preferably, the reinforcing sheet is located below a seam of the support board or panel The reinforcing sheet may be located in recesses provided within the support board or panel.

Preferably, the laminate comprises a layer of fibreglass located between layers of further layers, at least one of which is a solid surface material. For instance, the laminate may comprise a layer of fibreglass located between one or more layers of a solid surface material on both sides of the layer of fiberglass.

The support board or panel has a thickness of, for example, about 12mm.

The reinforcing sheet has a thickness of, for example, about 12mm or about 6mm.

Preferably, the solid surface material is made from an acrylic, epoxy or polyester resin and aluminium trihydrate. More preferably, the resin is methyl methacrylate.

Preferably, the methyl methacrylate is present in the solid surface material in an amount in the range of 35 to 45% by weight.

Preferably, the aluminium trihydrate is present in the solid surface material in an amount in the range 55 to 45% by weight.

The present invention further provides a method of reinforcing a support board or panel comprising securing to the support board or panel a reinforcing element of the invention Preferably, the reinforcing elcmentl is secured below a scam in the support board or panel.

For a better understanding of the invention and to show how embodiments of the same may be carried into effect, reference will now be made, by way of example, to the accompanying diagrammatic drawings, in which: Figure I shows a countertop, with a pair of panels glued together, and supported by a cleat; Figures 2 to 4 show embodiments of the present invention.

Embodiment of the present invention will now be described, by way of examples only, with reference to the accompanying drawings.

Referring to Figure 1 of the accompanying drawings, a countertop or worktop comprises SSM sheets 2 and 3 which are abutted at join 1. Sheets 2 and 3 are typically 12mm in depth but may have a different depth, for instance, 20nrun. A subframc, formed from elements 4 and 5 made from MDF of, typically 25mm depth, provides overall strength to the work-top. Located below join 1 is a cleat 6 formed from an SSM sheet having a depth of 12mm.

Referring to Figure 2 of the accompanying drawings, a countertop comprises SSM sheets 2 and 3 of, typically, 12mm depth and abutted at join 1. Sheets 2 and 3 are routed out at 7, below join 1, to accommodate a cleat which is a three layer laminate comprising an upper layer 4, a lower layer 5 and an intermediate layer 6. Upper and lower layers 4 and 5 are SSM sheets of, typically, 3mm depth and layer 6 is a fibreglass sheet which is secured to layers 4 and 5 by means of adhesive.

Referring to Figure 3 of the accompanying drawings, a countertop comprises SSM sheets 2 and 3 of, typically, 3n-un depth and abutted at join 1. A subframe, formed from elements 4 and 5 made from MDF or plywood and, typically, of 6mm depth, provides overall strength to the worktop. Located below join 1 is a cleat which is a three layer laminate comprising an upper layer 6, located directly below join 1, which is sheet of fibreglass which is provided with adhesive on both sides. Below layer 6 is a layer 7 which is an SSM sheet of, typically, 3mm depth. Below layer 7 is an optional further SSM layer 8 of, typically. 3mm depth.

Referring to Figure 4 of the accompanying drawings, a countertop comprises SSM sheets 2 and 3 of, typically, 3mm depth and abutted at join I. A subframe, formed from elements 4 and 5 made from MDF or plywood and, typically, of 6mm depth, provides overall strength to the worktop. Underlying sheets 2 and 3 is a fibreglass sheet of, typically, 3mm depth which is provided with adhesive on both sides and which is applied to all seams rather than just the joins. Located below join 1 is a cleat which is a three layer laminate comprising an upper layer 7, an optional lower layer 8 and an intermediate layer 9. Upper and lower layers 7 and 8 are SSM sheets of, typically, 3mm depth and layer 9 is a fibreglass sheet which is secured to layers 4 and 5 by means of adhesive.

In the above described embodiments the thickness of the components may vary.

For instance, the SSM sheets may have a depth of up to, and beyond, 20mm. Materials may vary, for instance, SSM. MDF and plywood being replaced by other suitable (similarly performing) materials.

In all embodiments, the inclusion of a cleat of SSM material vastly improves the impact, compression and shear stress capabilities of the countertop. The arrangement of the cleat can be applied to different third party sheet materials, to vastly improve on the performance of these sheet materials. These SSM cleat arrangements are not limited to countertops but could be used in other structures, such as a wall partition, wall or floor panel, or alternative surfaces within domestic and commercial environments, where strength of join is of paramount importance, whilst also providing a substantially seamless, and therefore hygienic, joint between panels. The countertop could equally be a support board or panel for any of these applications. One example of use would be where a configuration of panels is used as a partition, or to create cubicles, such as within public toilets and washrooms. Hygiene in such environments is paramount, and the SSM cleat ensures the joint between panels are seamless, and therefore very easy to clean.

A common thickness of the cleat is 6mm to suit existing worlctop and countertop configurations. The surface or countertop size that could be formed using this reinforcing system could be up to a length of 3.6m and a width of 0.9m, although lengths and widths in excess of these dimensions would also be possible.

The cleat may also be used as a reinforcing cleat in the fabrication of 12mm seamless acrylic worksurfaces. Traditionally, 12mm thick cleats are used to reinforce these seams, strengthening the material and preventing seam failure. The resulting surface sheet would therefore be in excess of 24mm thickness. An SSM cleat of 6nim thickness incorporated underneath a 12mm thick acrylic worksurface, results in an overall thickness of 18mm.

Typically, the number and location of any joins between panels has an impact on the thickness of surface that can be used. The reinforcements through the cleats allows for the panels to be used for a wider range of applications, as the overall thickness can replicate existing surfaces. The composite surface with SSM cleats could be for use as wall panelling, and in particular wall panelling in commercial environments such as airports and hotels, or within wet rooms and showers. The SSM cleat system can be used in a wide variety of thicknesses to suit the specific application.

In this specification, the verb "comprise" has its normal dictionary meaning, to denote non-exclusive inclusion. That is, use of the word "comprise" (or any of its derivatives) to include one feature or more, does not exclude the possibility of also including further features. The word "preferable" (or any of its derivatives) indicates one feature or more that is preferred but not essential All or any of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and/or all or any of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive.

Each feature disclosed in this specification (including any accompanying claims, abstract and drawings), may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features.

The invention is not restricted to the details of the foregoing embodiment(s). The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.

Claims

CLAIMS: 1. A reinforcing clement comprising a laminate comprising a layer of a solid surfacc material and a layer of fibreglass.
2. A support board or panel having a reinforcing element as claimed in Claim 1.
3 A support board or panel according to Claim 2, wherein the support board or panel is a worktop.
4. A support board or panel according to Claim 2, wherein the support board or panel is a door.
A support board or panel according to any of Claims 2 to 4, wherein said reinforcing element is located below a seam of the support board or panel.
6. A support board or panel according to any of Claims 2 to 5, wherein the reinforcing element is located in recesses provided within the support board or panel.
7 A support board or panel according to any of Claims 2 to 6, wherein the laminate comprises a layer of fibreglass located between layers of further layers at least one of which is a solid surface material.
8 A support board or panel according to Claim 7, wherein the laminate comprises a laver of fibreglass located between lavers of a solid surface material on both sides of the laver of fiberglass.0.
A support board or panel according to any of Claims 2 to 8, wherein the support board or panel has a thickness of about 12 nun
10. A support board or panel according to any of Claims 2 to 9, wherein the reinforcing element has a thickness of about 6mm.
11. A support board or panel according to any of Claims 2 to 10, wherein the solid surface material is made from an acrylic, epoxy or polyester resin and aluminium tri hydrate.
12. A support board or panel according to Claim 11, wherein the resin is methyl methamilate.
13. A support board or panel according to Claim 12, wherein the methyl methacrylate is present in the solid surface material in an amount in the range of 35 to 45% by weight.
14 A support board or panel according to any of Claims 11 to 13, wherein the aluminium trihydrate is present in the solid surface material in an amount in the range 55 to 45% by weight.
15. A method of reinforcing a support board or panel comprising securing to the support board or panel a reinforcing element as claimed in Claim 1.
16. A method according to Claim 15, wherein the solid surface material is secured below a scam in the support board or panel.