US20070234675A1 - Lightweight man-made board - Google Patents

Lightweight man-made board Download PDF

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Publication number
US20070234675A1
US20070234675A1 US11/378,905 US37890506A US2007234675A1 US 20070234675 A1 US20070234675 A1 US 20070234675A1 US 37890506 A US37890506 A US 37890506A US 2007234675 A1 US2007234675 A1 US 2007234675A1
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US
United States
Prior art keywords
board
face
base
center layer
intermediate
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.)
Abandoned
Application number
US11/378,905
Inventor
Xichuan Wang
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Panel Resources Inc
Original Assignee
Panel Resources Inc
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Panel Resources Inc filed Critical Panel Resources Inc
Priority to US11/378,905 priority Critical patent/US20070234675A1/en
Assigned to PANEL RESOURCES, INC. reassignment PANEL RESOURCES, INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: WANG, XICHUAN
Publication of US20070234675A1 publication Critical patent/US20070234675A1/en
Application status is Abandoned legal-status Critical

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    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04CSTRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/30Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
    • E04C2/38Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure with attached ribs, flanges, or the like, e.g. framed panels
    • E04C2/388Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure with attached ribs, flanges, or the like, e.g. framed panels with a frame of other materials, e.g. fibres, plastics
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04CSTRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/26Building 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
    • E04C2/284Building 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
    • E04C2/296Building 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 non-metallic or unspecified sheet-material

Abstract

A lightweight board has a face board, a base board, a center layer positioned between the face board and the base board, and a frame structure encircling the center layer between the face board and the base board, with the frame structure having a plurality of tubular sections. The face board, the base board and the center layer are combined to form a single unit.

Description

    BACKGROUND OF THE INVENTION
  • 1. Field of the Invention
  • The present invention relates to the technical field of man-made board materials, and in particular, to a type of lightweight man-made board.
  • 2. Description of the Related Art
  • Man-made board materials currently available on the market include particleboard, medium density fiberboard, plywood, etc. Since these boards perform similarly to solid wood and are easy to process, they are widely used in furniture manufacturing, decoration, and other fields.
  • Unfortunately, these board materials suffer from some disadvantages which limit their use in some applications. For example, since these board materials are relatively heavy, when they are used to manufacture exhibition panels or other shelves that require repeated transportation, they are often unable to meet the transportation weight requirements. Therefore, the user will sometimes use hollow boards as a substitute. However, this causes another problem since these hollow boards are not strong and often become deformed because they cannot support the weight of the exhibited products placed on these shelves.
  • Thus, there still remains a need for a lightweight board material that is strong enough to support heavy weights.
  • SUMMARY OF THE INVENTION
  • Accordingly, the present invention is directed to a board structure that substantially obviates one or more of the problems due to limitations and disadvantages of the related art.
  • It is an object of the present invention to provide a board that is lightweight yet is strong enough to support heavy weights.
  • Additional features and advantages of the invention will be set forth in the descriptions that follow and in part will be apparent from the description, or may be learned by practice of the invention. The objectives and other advantages of the invention will be realized and attained by the structure particularly pointed out in the written description and claims thereof as well as the appended drawings.
  • In order to accomplish the objects of the present invention, the present invention provides a board having a face board, a base board, a center layer positioned between the face board and the base board, and a frame structure encircling the center layer between the face board and the base board, the frame structure having a plurality of tubular sections fixed to the face board and the base board, and the face board, the base board and the center layer are combined to form a single unit.
  • It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory and are intended to provide further explanation of the invention as claimed.
  • BRIEF DESCRIPTION OF THE DRAWINGS
  • FIG. 1 is a cut-away perspective view of a board structure according to an embodiment of the present invention.
  • FIG. 2 is an enlarged view of a portion of the structure of FIG. 1.
  • FIG. 3 is a cut-away perspective view of a board structure according to another embodiment of the present invention.
  • FIG. 4 is an enlarged view of a portion of the structure of FIG. 3.
  • DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
  • The following detailed description is of the best presently contemplated modes of carrying out the invention. This description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating general principles of embodiments of the invention. The scope of the invention is defined by the appended claims.
  • FIGS. 1 and 2 illustrate one embodiment of a lightweight man-made board that includes a face board 1, a base board 2, and a center layer 3 that are combined as a single unit. The center layer 3 is positioned between the face board 1 and the base board 2. A frame structure comprised of tubular sections 31 is provided on the four sides of the center layer 3 to encircle the center layer 3. The two surfaces of the frame structure are adhered to the face board 1 and the base board 2. An intermediate board 32 is arranged in the cavity enclosed by the tubular sections 31, the face board 1 and the base board 2, and is fixed in the cavity by support blocks 33 that are connected to the face board 1 and the base board 2. There is a space left between the intermediate board 32 and the face board 1 and the base board 2. A space is also left between the tubular sections 31 and the support blocks 33. All of these spaces are filled with a filler 34. Several installation grooves 4 used for hanging goods can be formed in the outer surface of the face board 1, as long as the intermediate board 32 in the center layer 3 has sufficient thickness and strength.
  • The tubular sections 31 may be hollow plastic tube sections. The intermediate board 32 may be made of a medium density fiberboard with sufficient strength. The filler 34 may be light foam. The support blocks 33 may be solid wood blocks.
  • In this embodiment, since hollow plastic tubes are used as tubular sections 31, the weight of the overall structure is reduced while sufficient strength is provided. In addition, the entire frame structure formed by the tubular sections 31 can prevent moisture from entering the center layer 3, and the entire board can be prevented from experiencing deformation caused by moisture. In order to reduce the weight while providing the overall board with sufficient strength, a stable box structure is formed inside center layer 3. This box structure is formed by the intermediate board 32 made of a medium density fiberboard, support blocks 33 fixed on the four sides of the intermediate board 32, and the base board 2. The box structure is integrated with the face board 1 through the support blocks 33. This provides the lightweight man-made board with sufficient bending strength. Therefore, even when installation grooves 4 are formed in the surface of the face board 1 and goods are hung on the board, the overall board will not experience bending deformation. Also, the light filler 34 that is filled in the hollow parts of the central layer prevents the face board 1 and the base board 2 from caving in due to local stress, without increasing the overall weight of the board.
  • FIGS. 3 and 4 illustrate modifications made to the lightweight man-made board in FIGS. 1 and 2. The difference between this embodiment and the embodiment in FIGS. 1 and 2 is that the installation grooves 4 are formed in the outer surface of both the face board 1 and the base board 2, and a reinforcing board 35 is added between the intermediate board 32 and the face board 1 inside the center layer 3. The reinforcing board 35 is fixed to the face board 1 and the base board 2 with the aid of the support blocks 33 fixed on its four sides. A filler 34 fills the space left between the reinforcing board 35 and the face board 1.
  • In the board of FIGS. 3 and 4, the intermediate board 32 and the reinforcing board 35 in the center layer 3 form two stable box structures with the support blocks 33 as well as the face board 1 and the base board 2. The two box structures are both integrated with the face board 1 and the base board 2. The overall strength of the board is further increased in this way. Also, the symmetrical nature of the board further guarantees the anti-deformation capability of the lightweight man-made board.
  • The boards according to embodiments of the present invention have the following features and benefits. The board has a three-layer structure that includes a face board 1, a center layer 3, and a base board 2. The surrounding sides of the intermediate board 32 are sealed with a frame structure. The three layers are therefore combined into a single unit, and the frame structure can thus prevent the entire board from experiencing warping deformation. Since the center layer 3 has many hollow parts that are filled with a light filler 34, the overall weight of the board is reduced. This solves the problem of excessive weight during transportation.
  • In addition, in order to provide the board with sufficient strength, an intermediate board 32 with certain strength is added inside the frame structure of the center layer 32. The support blocks 33 fixed on the enclosing sides of the intermediate board 32 enable the intermediate board 32 to form a stable box structure together with the base board 2. This gives the overall board sufficient bending strength. Thus, even if installation grooves are formed in the face board 1, the overall strength of the board will not be affected. When the frame structure is made of a hollow plastic material, moisture can be prevented from penetrating into the center layer 3. The entire board can thereby be prevented from experiencing deformation caused by moisture.
  • While the description above refers to particular embodiments of the present invention, it will be understood that many modifications may be made without departing from the spirit thereof. The accompanying claims are intended to cover such modifications as would fall within the true scope and spirit of the present invention.

Claims (12)

1. A board comprising:
a face board;
a base board;
a center layer positioned between the face board and the base board; and
a frame structure encircling the center layer between the face board and the base board, the frame structure having a plurality of tubular sections fixed to the face board and the base board,
wherein the face board, the base board and the center layer are combined into a single unit.
2. The board of claim 1, wherein a space defined between the face board and the base board is filled with a filler.
3. The board of claim 1, wherein a cavity is defined by the face board, the base board, and the frame structure, and the center layer further includes an intermediate board arranged in the cavity.
4. The board of claim 3, wherein the intermediate board is fixed in the cavity by support blocks that are connected to the face board and the base board.
5. The board of claim 3, further comprising a reinforcing board arranged between the intermediate board and the face board.
6. The board of claim 5, wherein the intermediate board and the reinforcing board are fixed to the face board and the base board by support blocks.
7. The board of claim 1, further comprising installation grooves formed in the face board.
8. The board of claim 1, further comprising installation grooves formed in the base board.
9. The board of claim 1, wherein the tubular sections of the frame structure are made of hollow plastic tubes.
10. The board of claim 2, wherein the filler is a light foam.
11. The board of claim 3, wherein the intermediate board is made of a medium density fiberboard, particleboard, or plywood.
12. The board of claim 4, wherein the support blocks are made of solid wood.
US11/378,905 2006-03-17 2006-03-17 Lightweight man-made board Abandoned US20070234675A1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
US11/378,905 US20070234675A1 (en) 2006-03-17 2006-03-17 Lightweight man-made board

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US11/378,905 US20070234675A1 (en) 2006-03-17 2006-03-17 Lightweight man-made board

Publications (1)

Publication Number Publication Date
US20070234675A1 true US20070234675A1 (en) 2007-10-11

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Citations (28)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2840353A (en) * 1952-08-29 1958-06-24 Paul M Muspratt Radiant heating panel
US3030687A (en) * 1958-06-23 1962-04-24 Paul M Muspratt Method and apparatus for producing a monolithic concrete construction panel
US3679529A (en) * 1969-08-12 1972-07-25 Architectural Res Corp Panel construction
US3908324A (en) * 1973-09-20 1975-09-30 Robert K Stout Concrete structure including modular concrete beam and method of making same
US4719738A (en) * 1982-11-22 1988-01-19 Lee Chang Y Block
US5279089A (en) * 1992-03-19 1994-01-18 Gulur V Rao Insulated wall system
US5444955A (en) * 1994-01-31 1995-08-29 An Shun Enterprise Co., Ltd. Combination wall
US5927032A (en) * 1997-04-25 1999-07-27 Record; Grant C. Insulated building panel with a unitary shear resistance connector array
US6295786B1 (en) * 1997-08-11 2001-10-02 John Bartholomew Lee Building panel and method of forming same
US20020014051A1 (en) * 2000-04-20 2002-02-07 Fraval Hanafi R. High strength light-weight fiber ash composite material, method of manufacture thereof, and prefabricated structural building members using the same
US6378261B1 (en) * 1999-07-13 2002-04-30 Carl F. Agsten Wall system involving panels
US20020053176A1 (en) * 2000-04-24 2002-05-09 Colson Wendell B. Compressible structural panel
US20030150182A1 (en) * 2002-02-13 2003-08-14 Ju-Li Chou Structural member
US20030159400A1 (en) * 2000-01-13 2003-08-28 Trevor Forrester Building panels
US6711872B2 (en) * 2001-07-30 2004-03-30 International Paper Company Lightweight panel construction
US20040074205A1 (en) * 2000-07-17 2004-04-22 Michael Stache Self-and load-supporting component
US6739104B2 (en) * 2001-05-18 2004-05-25 Jamco Corporation Vacuum heat-insulating block
US20040177590A1 (en) * 2003-03-14 2004-09-16 Thomas Nudo Composite structural panel and method
US20040237465A1 (en) * 2001-12-17 2004-12-02 Benny Refond Plateformed building element comprising zigzag shaped lamellae
US6845591B1 (en) * 1999-09-24 2005-01-25 Vbi Ontwikkeling B.V. Hollow-core slab for forming a floor field in which ducts can be incorporated, and method for forming a floor field with ducts using such hollow-core slabs
US7107731B2 (en) * 1997-04-25 2006-09-19 Leep, Inc. Insulated asymmetrical directional force resistant building panel with symmetrical joinery, integral shear resistance connector and thermal break
US20060260271A1 (en) * 2000-04-24 2006-11-23 Hunter Douglas Inc. Structural panel with compressible dividers
US20070033899A1 (en) * 2005-07-20 2007-02-15 Kabushiki Kaisha Kobe Seiko Sho (Kobe Steel, Ltd.) Extruded hollow aluminum alloy panel and method for producing the same
US20070169432A1 (en) * 2003-12-03 2007-07-26 Bridge Iain N Panel structure
US7254925B2 (en) * 1999-02-09 2007-08-14 Efficient Building Systems, L.L.C. Insulated wall assembly
US20070261364A1 (en) * 2006-05-11 2007-11-15 Gordon Ritchie Mould resistant sandwich panel
US20080086982A1 (en) * 2006-09-19 2008-04-17 Martin Parenteau Insulating panel and process of making same
US7421830B1 (en) * 2002-09-24 2008-09-09 Extrutech International, Inc. Layered composites

Patent Citations (28)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2840353A (en) * 1952-08-29 1958-06-24 Paul M Muspratt Radiant heating panel
US3030687A (en) * 1958-06-23 1962-04-24 Paul M Muspratt Method and apparatus for producing a monolithic concrete construction panel
US3679529A (en) * 1969-08-12 1972-07-25 Architectural Res Corp Panel construction
US3908324A (en) * 1973-09-20 1975-09-30 Robert K Stout Concrete structure including modular concrete beam and method of making same
US4719738A (en) * 1982-11-22 1988-01-19 Lee Chang Y Block
US5279089A (en) * 1992-03-19 1994-01-18 Gulur V Rao Insulated wall system
US5444955A (en) * 1994-01-31 1995-08-29 An Shun Enterprise Co., Ltd. Combination wall
US5927032A (en) * 1997-04-25 1999-07-27 Record; Grant C. Insulated building panel with a unitary shear resistance connector array
US7107731B2 (en) * 1997-04-25 2006-09-19 Leep, Inc. Insulated asymmetrical directional force resistant building panel with symmetrical joinery, integral shear resistance connector and thermal break
US6295786B1 (en) * 1997-08-11 2001-10-02 John Bartholomew Lee Building panel and method of forming same
US7254925B2 (en) * 1999-02-09 2007-08-14 Efficient Building Systems, L.L.C. Insulated wall assembly
US6378261B1 (en) * 1999-07-13 2002-04-30 Carl F. Agsten Wall system involving panels
US6845591B1 (en) * 1999-09-24 2005-01-25 Vbi Ontwikkeling B.V. Hollow-core slab for forming a floor field in which ducts can be incorporated, and method for forming a floor field with ducts using such hollow-core slabs
US20030159400A1 (en) * 2000-01-13 2003-08-28 Trevor Forrester Building panels
US20020014051A1 (en) * 2000-04-20 2002-02-07 Fraval Hanafi R. High strength light-weight fiber ash composite material, method of manufacture thereof, and prefabricated structural building members using the same
US20020053176A1 (en) * 2000-04-24 2002-05-09 Colson Wendell B. Compressible structural panel
US20060260271A1 (en) * 2000-04-24 2006-11-23 Hunter Douglas Inc. Structural panel with compressible dividers
US20040074205A1 (en) * 2000-07-17 2004-04-22 Michael Stache Self-and load-supporting component
US6739104B2 (en) * 2001-05-18 2004-05-25 Jamco Corporation Vacuum heat-insulating block
US6711872B2 (en) * 2001-07-30 2004-03-30 International Paper Company Lightweight panel construction
US20040237465A1 (en) * 2001-12-17 2004-12-02 Benny Refond Plateformed building element comprising zigzag shaped lamellae
US20030150182A1 (en) * 2002-02-13 2003-08-14 Ju-Li Chou Structural member
US7421830B1 (en) * 2002-09-24 2008-09-09 Extrutech International, Inc. Layered composites
US20040177590A1 (en) * 2003-03-14 2004-09-16 Thomas Nudo Composite structural panel and method
US20070169432A1 (en) * 2003-12-03 2007-07-26 Bridge Iain N Panel structure
US20070033899A1 (en) * 2005-07-20 2007-02-15 Kabushiki Kaisha Kobe Seiko Sho (Kobe Steel, Ltd.) Extruded hollow aluminum alloy panel and method for producing the same
US20070261364A1 (en) * 2006-05-11 2007-11-15 Gordon Ritchie Mould resistant sandwich panel
US20080086982A1 (en) * 2006-09-19 2008-04-17 Martin Parenteau Insulating panel and process of making same

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Legal Events

Date Code Title Description
AS Assignment

Owner name: PANEL RESOURCES, INC., CALIFORNIA

Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:WANG, XICHUAN;REEL/FRAME:017805/0451

Effective date: 20060316