LV14893B - Multi-layer composite material having corrugated cardboard layer and a method for making thereof - Google Patents

Abstract

The invention relates to a multiple layer light weight panel and its manufacturing method. The panel consists of a middle layer, made from multiple layer material, such as sheets of multi-layer corrugated cardboard layers of which are sorted perpendicularly to each other by their flute direction, and the outer layers, which may be a thin wood panel material such as MDF boards.

Description

DESCRIPTION OF THE INVENTION

The present invention, a composite composite material with a corrugated cardboard core layer, and a method for making it, is applicable to the Materials Science sub-sector "Wood Materials and Technology". Multiple applications of wood-cardboard composite materials include packaging materials, decorative and barrier interior elements, furniture and other products [1]. Composite material structure for slab materials increases material stiffness and load-bearing capacity [2; 3],

The US patent [4] describes a plurality of corrugated cardboard sheets with mutually perpendicular corrugation direction. U.S. Patents [5] and [6] describe methods and apparatus for making such a cardboard sheet. This material is made of three layers of corrugated cardboard, which consists of a corrugated cardboard middle layer and cardboard cover layers. These sheets are interconnected perpendicular to the direction of corrugation to form a plurality of corrugated cardboard sheets. Such material can be used as middle layer in wood composite materials [1; 7].

Such material can also be obtained by joining, preferably by gluing, the packaging material, three layers of corrugated cardboard, in several layers perpendicular to the direction of corrugation. The resulting multi-ply corrugated board with a mutually perpendicular direction of corrugation can be used as a middle layer in wood composite materials [8].

The purpose of the present invention is to increase the useful yield of cellulosic material and wood by reducing the structural weight of the wood panels while maintaining high mechanical properties [2],

The invention describes a multiple lightweight composite panel and a method for manufacturing such panels. The product consists of three components: the top layer, the middle layer and the bottom layer. The cladding layers cover the middle layer on both sides. The middle layer is a multi-layered cellulosic material, preferring a prefabricated sheet of corrugated cardboard with a mutually perpendicular direction of corrugation. Multiple layers of corrugated cardboard with mutually perpendicular direction of corrugation are made of three layers of corrugated cardboard, preferring prefabricated three-layer corrugated cardboard sheets. The surface cladding material is made of thin board material, with a preference for medium density fiber board material (MDF), but can be used: plywood, particle board or other board material.

This results in a composite material with a lower bulk density than the same thickness of wood-based board and a higher load-bearing capacity than the same thickness of multi-corrugated board [8],

This invention will be better understood by reference to the illustrative drawings:

Figure 1 illustrates the structure of a composite middle layer of multiple corrugated cardboard sheets with a mutually perpendicular direction of corrugation;

Figure 2 shows the surface layer and the middle layer structure of the composite medium density fiber board;

Figure 3 shows a finished composite panel.

Figure 1 shows a middle layer (3), the construction of which is preferably made of a pre-fabricated sheet of corrugated cardboard having a mutually perpendicular direction of corrugation. Multiple layers of corrugated cardboard may also be used, which are perpendicular to each other, preferably with gluing.

Figure 2 shows a layered material consisting of a plurality of layers (1), (2) of a middle layer (3) of a corrugated cardboard and a surface facing. This material is made by interconnecting the composite layers, preferring to be press-pressed. The thickness of the middle layer (3) may vary depending on the thickness of the finished composite panel required and the thickness of the top layer (1) and the bottom layer (2). The size of the composite material components (1), (2) and (3) can be varied depending on the size of the finished composite panel format required or the size of the press plates used to make it.

Figure 3 shows a ready-made composite panel consisting of surface facing layers (1), (2) and a center layer (3), wherein the total panel length, width and thickness are unlimited and can be customized to the consumer's requirements.

The basis of the present invention is the construction of a composite material structure consisting of a middle layer bonding, with preference for gluing, with layers of surface cladding. The binder (adhesive) may be applied to the middle or to the surfaces of the plating layers or to the planes of all the components of the composite material. Application of the binder can be effected, for example, by the casting or roller method, passing through the adhesive rollers on which the binder is applied.

To improve adhesion, the assembled (stacked) composite structure is pressurized. Press plates can be unheated or heated, depending on the choice of binder [9]. The finished panels can be further cut to size.

Multi-layer composite material with corrugated cardboard core layer is intended for light weight enclosing elements - office work area separation panels, interior elements, etc .; packaging materials - high strength boxes, cases, enclosures in containers, etc.

LITERATURE

1. Stosch, M. Lightweight Design. BM Special: Fachmagazin fīir Innenausbau, Mobel, Bauelemente. Leinfelden-Echterdingen: Konradin Verlag, 2009.

2. Askeland, D.R., Fulay, P.P. Essentials of Materials Science and Engineering, Second Edition.

Toronto; Cengage Leaming, 2009. 543.; 578.-579. p.

3. Peter, A. Design of Sandwich Structures. Dissertation. Cambridge University Engineering Department. Cambridge: Robinson College, 1998.

4. U.S. Pat. 4128677,1978, Multi-flute-layer corrugated board.

5. U.S. Pat. 4126508, 1978, Apparatus for forming a multi-flute-layer corrugated board.

6. U.S. Pat. 4435237, 1984, Method for forming a multi-flute-layer corrugated board.

7. Seidl, R.J. Paper-honeycomb cores for structural sandwich panels. Madison: United States Department of Agriculture, Forest Service, Forest Products Laboratory, 1956.

8. Metums, J. Use of Corrugated Cardboard in the Production of Lightweight Panels. Diploma paper. Jelgava:

LUA Woodworking Department, 2012.

9. Dunky, M., Niemz, P. Elolzwerkstoffe und Leime - Technologie und Einflussfaktoren. Berlin: Springer Verlag, 2002. 249.-554. p.

Claims (2)

A composite panel comprising three layers, wherein the middle layer (3) comprises multiple layers of corrugated cardboard with a mutually perpendicular direction of corrugation, characterized in that the material of the top layer (1) and the bottom layer (2) is made of wood panels. material. A method of manufacturing a composite panel according to claim 1, comprising the steps of: forming a composite material by gluing its layers (1), (2) and (3) under pressure in a press.