SG184593A1 - Thermoplastic covered composite board - Google Patents
Thermoplastic covered composite board Download PDFInfo
- Publication number
- SG184593A1 SG184593A1 SG2011020989A SG2011020989A SG184593A1 SG 184593 A1 SG184593 A1 SG 184593A1 SG 2011020989 A SG2011020989 A SG 2011020989A SG 2011020989 A SG2011020989 A SG 2011020989A SG 184593 A1 SG184593 A1 SG 184593A1
- Authority
- SG
- Singapore
- Prior art keywords
- layer
- composite board
- hard plastic
- bonded
- board according
- Prior art date
Links
- 239000002131 composite material Substances 0.000 title claims abstract description 48
- 229920001169 thermoplastic Polymers 0.000 title claims abstract description 6
- 239000004416 thermosoftening plastic Substances 0.000 title claims abstract description 6
- 239000000463 material Substances 0.000 claims abstract description 94
- 229920003023 plastic Polymers 0.000 claims abstract description 27
- 239000004033 plastic Substances 0.000 claims abstract description 27
- 239000002023 wood Substances 0.000 claims abstract description 7
- -1 polyethylene Polymers 0.000 claims description 12
- 239000004698 Polyethylene Substances 0.000 claims description 8
- 229920000573 polyethylene Polymers 0.000 claims description 8
- 239000011120 plywood Substances 0.000 claims description 6
- XTEGARKTQYYJKE-UHFFFAOYSA-M Chlorate Chemical compound [O-]Cl(=O)=O XTEGARKTQYYJKE-UHFFFAOYSA-M 0.000 claims description 4
- 239000004743 Polypropylene Substances 0.000 claims description 4
- 239000004676 acrylonitrile butadiene styrene Substances 0.000 claims description 4
- 238000000034 method Methods 0.000 claims description 4
- 229920001155 polypropylene Polymers 0.000 claims description 4
- XECAHXYUAAWDEL-UHFFFAOYSA-N acrylonitrile butadiene styrene Chemical compound C=CC=C.C=CC#N.C=CC1=CC=CC=C1 XECAHXYUAAWDEL-UHFFFAOYSA-N 0.000 claims description 3
- 229920000122 acrylonitrile butadiene styrene Polymers 0.000 claims description 3
- 238000010030 laminating Methods 0.000 claims description 3
- 239000002245 particle Substances 0.000 claims description 3
- 229920002554 vinyl polymer Polymers 0.000 claims description 2
- 239000007767 bonding agent Substances 0.000 claims 1
- 238000009416 shuttering Methods 0.000 description 16
- 239000000853 adhesive Substances 0.000 description 7
- 230000001070 adhesive effect Effects 0.000 description 7
- 238000010276 construction Methods 0.000 description 6
- 238000004519 manufacturing process Methods 0.000 description 4
- 229910000831 Steel Inorganic materials 0.000 description 2
- 230000007613 environmental effect Effects 0.000 description 2
- 229920000915 polyvinyl chloride Polymers 0.000 description 2
- 239000004800 polyvinyl chloride Substances 0.000 description 2
- 239000010959 steel Substances 0.000 description 2
- 230000003466 anti-cipated effect Effects 0.000 description 1
- 230000015556 catabolic process Effects 0.000 description 1
- 230000001010 compromised effect Effects 0.000 description 1
- 238000006731 degradation reaction Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 230000002708 enhancing effect Effects 0.000 description 1
- 238000009415 formwork Methods 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 230000000149 penetrating effect Effects 0.000 description 1
- 238000004064 recycling Methods 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 230000035899 viability Effects 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
Classifications
-
- 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
- B32B21/00—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board
- B32B21/04—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B21/08—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04G—SCAFFOLDING; FORMS; SHUTTERING; BUILDING IMPLEMENTS OR AIDS, OR THEIR USE; HANDLING BUILDING MATERIALS ON THE SITE; REPAIRING, BREAKING-UP OR OTHER WORK ON EXISTING BUILDINGS
- E04G9/00—Forming or shuttering elements for general use
- E04G9/02—Forming boards or similar elements
- E04G9/05—Forming boards or similar elements the form surface being of plastics
-
- 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
- B32B21/00—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board
- B32B21/12—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board next to a particulate layer
Abstract
THERMOPLASTIC COVERED COMPOSITE BOARDA composite board comprising a first layer of material consisting of one material from a first hard plastic material set; a second layer consisting of a wood material; a third layer of material consisting of one material from the first hard plastic material set; where the layers are bonded in a sequential fashion; a fourth layer of material consisting of one material from the hard plastic material set bonded to one edge of the board; and a fifth layer of material consisting of one material from the hard plastic material set bonded to a second edge of the board.FIG. 1
Description
THERMOPLASTIC COVERED COMPOSITE BOARD
The invention relates to a composite board. The invention is particularly suitable for use as a shuttering board and it is in this context that the invention will be described.
The following discussion of the background to the invention is intended to facilitate an understanding of the present invention. However, it should be appreciated that the discussion is not an acknowledgment or admission that any of the material referred to was published, known or part of the common general knowledge in any jurisdiction as at the priority date of the application.
Outdoor constructions require material that are suited to withstand the effects of the weather such as rain and other environmental factors. Such material must also be durable in situations where the outdoor construction is anticipated to be a permanent construction.
Some of the current materials used in outdoor construction as not environmentally friendly. Alternative materials break easily.
Shuttering boards are commonly used at construction sites to maintain poured concrete in a desired shape. It is particularly used in maintaining poured concrete that, when set, forms a vertical pylon or the like. This process of maintaining the poured concrete in predefined shapes is also known as formwork.
There are essentially three types of shuttering boards that can be used:
Plywood shuttering boards. Such shuttering boards are cheap. But subject to degradation with each use. As a result, plywood shuttering boards are often re-used somewhere between 8 to 10 times before they need to be changed. Changing such shuttering boards consumes additional labour and material costs. Furthermore, the used plywood shuttering boards must be disposed of in some manner, often by incineration, which creates further environmental problems.
Steel shuttering boards. Being made of a more durable material, steel shuttering boards may be re-used up to 100 times before needing to be changed. However, this durability is also a disadvantage as such shuttering boards are difficult to handle and shape at the construction site.
Plastic shuttering boards. Plastic shuttering boards have been introduced to the market with limited success. The main reasons for this lack of success has been their low strength to weight ratio. While some attempts to improve the strength to weight ratio of plastic shuttering boards have been technically successful, it has been done at such a high production cost that the commercial viability of such boards has been significantly compromised.
It is therefore an object of the present invention to produce a composite board which overcomes, or at least ameliorates in part, one or more of the aforementioned problems.
Throughout this document, unless otherwise indicated to the contrary, the terms “comprising”, “consisting of”, and the like, are to be construed as non-exhaustive, or in other words, as meaning “including, but not limited to”.
In accordance with a first aspect of the invention there is a composite board comprising three layers of material, the first layer of material consisting of one material from a first hard plastic material set, the middle layer consisting of a wood material, a third layer of material consisting of one material from a first hard plastic material set, where the layers are bonded in a sequential fashion; a fourth layer of material consisting of one material from the hard plastic material set bonded to one edge of the board; and a fifth layer of material consisting of one material from the hard plastic material set bonded to a second edge of the board.
The first layer of material and the third layer of material are thermally bonded or jointed to the fourth layer of material and the fifth layer of material to form thermoplastic edge sealed joints.
Ideally, the material used in the first layer is also used in the third layer. This allows ease of manufacturing as the number of materials needed for manufacturing to be significantly reduced.
The first hard plastic material set, preferably, includes polyethylene; polypropylene; polyvinyl chlorate; acrylonitrile-butadiene-styrene.
The third layer preferably includes plywood, medium density fibreboard, particle board or plank.
It is preferred that the composite board has a thickness between 6 and 50mm with the ideal thickness of the composite board being between 10 and 18mm. Boards in the range 10 to 18mm provide the best overall performance and are relatively easy to manufacture compared to boards of other sizes.
The proportions between the differing layers may vary, but ideally the size of the first -and third layers do not exceed 3mm in thickness. It is also preferred that the thickness of the second layer, as a proportion of the total thickness of the composite board, remains at substantially 80%.
Thermal bonding may be used to sequentially bind each layer to its next layer. It is further preferred that any such bond be waterproof.
In accordance with a second aspect of the present invention there is a method of producing a composite board comprising the steps of: bonding a first layer made of a material from a hard plastic material set to a second layer made of a wood material; bonding the second layer to a third layer made of a material from a hard plastic material set;
A bonding a fourth layer of material consisting of one material from a hard plastic material set bonded to one edge of the board; bonding a fifth layer of material consisting of one material from a hard plastic material set bonded to a second edge of the board; and laminating the bonded board.
The invention will now be described, by way of example only, with reference to the accompanying drawings, in which:
Figure 1 is a plan view of a composite board according to the present invention.
In accordance with a first embodiment of the invention there is a composite board 10 of 18mm thickness (T). The composite board 10 comprises three layers of various material compositions. The first layer 12 and the third layer 14 are made of polyethylene to a thickness of 1.5mm. The second layer 16 consists of a wood material such as plywood. In this embodiment, the polyethylene of the middle layer 16 is solid state polyethylene. The second layer has a thickness of 14.4mm. The composite board 10 further comprises a fourth layer 18 and a fifth layer 20 made of polyethylene to a thickness of 1.5mm each. The length and width of the composite board are 2440mm and 1220mm respectively.
Each layer is thermally bonded to the layer below by adhesives to provide additional strength to the composite board 10 and to make the resulting composite board 10 waterproof. The adhesives are applied evenly on each layer. In this manner, first layer 12 is thermally bonded by adhesive to second layer 16, which is in turn thermally bonded by adhesive to third layer 14 and so on. The fourth layer 18 is thermally bonded by adhesive to an edge of the composite board 10 and the fifth layer 20 is in turn thermally bonded by adhesive to the other edge of the composite board 10. The first layer 12 and the third layer 14 are thermally bonded or jointed to the fourth layer 18 and the fifth layer 20 to form thermoplastic edge sealed joints 22,
24 that prevent water or moisture from penetrating into the middle layer, thereby enhancing the lifespan of the composite board. The whole composite board is then applied under heavy loads for a certain duration until the adhesives are set. The whole composite board is then laminated using conventional laminating techniques.
The applicant has found that the re-use cycle of composite boards made in accordance with the invention, and used as shuttering boards, ranges from 200 to 500 uses. Furthermore, such composite shuttering boards are completely recyclable.
The inherent strength of the composite boards also makes them suitable for other uses such as non-load bearing walls, scaffolding boards, floor decking, roofing shelters and truck cabins.
It should be appreciated by the person skilled in the art that the above invention is not limited to the embodiment described. In particular, the following modifications and improvements may be made without departing from the scope of the present invention: e The polyethylene ‘material used in the first and third layers may be replaced with other hard plastic materials such as polyvinyl chloride, polypropylene or ABS. e The wood material used in the second layer may be replaced with medium density fibreboard, particle board or plank. e The polyethylene material used in the fourth layer 18 and the fifth layer 20 may be replaced with other hard plastic materials such as polyvinyl chloride, polypropylene or acrylonitrile-butadiene-styrene (ABS). : e The material used in the second layer may be of virgin or recycled origin.
In this manner, new composite boards may be made by recycling the material used in older composite boards. e The thickness of the composite board may vary from the 18mm described above. While the preferred thickness range identified by the applicant is from 6mm to 50mm thickness, boards of other sizes may just as easily be created. e The thickness of the first and third layers should be limited to a maximum of 3mm for any composite board less than or equal to 50mm in thickness (total). e The thickness of the second layer, as a proportion of the total thickness of the composite board, should be roughly 80%. e The first layer 12 and the third layer 14 may have a flat, smooth surface or a textured surface so as to improve friction on the surface of the board for anti-skid purposes. e The length and width of the composite board may vary from the 2440mm and 1220mm described above. While the preferred length and width range identified by the applicant is from 50mm to 6000mm and 50 mm to 2000mm respectively, boards of other sizes may just as easily be created.
It should be further appreciated by the person skilled in the art that the features described above, where not mutually exclusive, can be combined to form yet further embodiments of the invention.
Claims (13)
1. A composite board comprising: a first layer of material consisting of one material from a hard plastic material set; a second layer consisting of a wood material; a third layer of material consisting of one material from the hard plastic material set; where the layers are bonded in a sequential fashion; a fourth layer of material consisting of one material from the hard plastic material set bonded to one edge of the board; and a fifth layer of material consisting of one material from the hard plastic material set bonded to a second edge of the board.
2. A composite board according to claim 1, where the first layer of material and the third layer of material are thermally bonded or jointed to the fourth layer of material and the fifth layer of material to form thermoplastic edge sealed joints.
3. A composite board according to claim 1 or 2, where the hard plastic material set comprises the materials: polyethylene; polypropylene; polyvinyl chlorate; acrylonitrile-butadiene-styrene. :
4. A composite board according to any preceding claim, where the second layer of material is plywood, medium density fibreboard, particle board or plank.
5. A composite board according to any preceding claim where the total thickness of the composite board is between 6 and 50mm.
6. A composite board according to claim 5, where the total thickness of the composite board is between 10 and 18mm.
7. A composite board according to claim 5 or claim 6, where the thickness of the first and fifth layers does not exceed 3 mm.
8. A composite board according to any preceding claim, where the thickness of the second layer represents substantially 80% of the total thickness of the composite board.
9. A composite board according to any preceding claim where each layer is thermally bonded to the next layer in sequence.
10. A composite board according to claim 9, where the bonding agent used is waterproof.
11. A composite board according to any preceding claim, where the material used in the first layer is the same as the material used in the third layer.
12. A method of producing a composite board comprising the steps of: bonding a first layer made of a material from a hard plastic material set to a second layer made of a wood material, bonding the second layer to a third layer made of a material from a hard plastic material set; bonding a fourth layer of material consisting of one material from a hard plastic material set bonded to one edge of the board; bonding a fifth layer of material consisting of one material from a hard plastic material set bonded to a second edge of the board; and laminating the bonded board.
13. A composite board substantially as described herein with reference to the drawings.
Priority Applications (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| SG2011020989A SG184593A1 (en) | 2011-03-24 | 2011-03-24 | Thermoplastic covered composite board |
| PCT/SG2012/000099 WO2012128723A1 (en) | 2011-03-24 | 2012-03-23 | Edge sealed composite board |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| SG2011020989A SG184593A1 (en) | 2011-03-24 | 2011-03-24 | Thermoplastic covered composite board |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| SG184593A1 true SG184593A1 (en) | 2012-10-30 |
Family
ID=46879627
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| SG2011020989A SG184593A1 (en) | 2011-03-24 | 2011-03-24 | Thermoplastic covered composite board |
Country Status (2)
| Country | Link |
|---|---|
| SG (1) | SG184593A1 (en) |
| WO (1) | WO2012128723A1 (en) |
Families Citing this family (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2015047189A1 (en) * | 2013-09-27 | 2015-04-02 | Wei Fern Choo | System and method of making composite boards |
| CN105064677B (en) * | 2015-08-11 | 2017-07-28 | 山东明达建筑科技有限公司 | Mortar leakage prevention rubber form and its construction method |
| CN111945975A (en) * | 2020-06-17 | 2020-11-17 | 程建平 | Manufacturing method and structure of melamine veneer without seam edge |
Family Cites Families (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CA2511002C (en) * | 2004-07-06 | 2012-10-23 | Minh-Tan Ton-That | Hot-melt adhesive |
| ITSV20060014A1 (en) * | 2006-05-22 | 2007-11-23 | Europlastica S R L | PANEL FOR THE REALIZATION OF FORMWORK CONTAINMENT WALLS FOR CONCRETE FLOOR PLANTS IN PARTICULAR FOR THE CONTAINMENT FORM FOR THE CONSTRUCTION OF CONCRETE OR SIMILAR INSOLES AND PROCEDURE FOR THE MANUFACTURE OF DETAILS |
| US8431642B2 (en) * | 2008-06-09 | 2013-04-30 | Exxonmobil Chemical Patents Inc. | Polyolefin adhesive compositions and articles made therefrom |
| FR2932491B1 (en) * | 2008-06-13 | 2010-08-27 | Bostik Sa | NOVEL THERMOFUSIBLE ADHESIVE COMPOSITION BASED ON POLYAMIDE |
| IT1394199B1 (en) * | 2009-02-11 | 2012-06-01 | Amaro Timber Ltd | PANEL FOR FORMWORN CONTAINMENT WALLS FOR CONCRETE CUTS IN PARTICULAR FOR THE CONTAINMENT FORM OF CONCRETE OR SIMILAR INSOLES |
-
2011
- 2011-03-24 SG SG2011020989A patent/SG184593A1/en unknown
-
2012
- 2012-03-23 WO PCT/SG2012/000099 patent/WO2012128723A1/en active Application Filing
Also Published As
| Publication number | Publication date |
|---|---|
| WO2012128723A1 (en) | 2012-09-27 |
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