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A composite panel and a method for making the same
The present invention relates to a method for making a composite panel of the type comprising a board made from a fibre material and a cover sheet or plate fastened to one or more side surfaces of the board. Such composite panel consisting of a solid board made from wooden particles and having one or more side surfaces covered by a cover sheet or plate made from veneer or plastics material are well known.
The present invention provides a method for making a composite panel of this type allowing a substantial reduction of the total weight of the panel without substantially diminishing the panel strength. Thus, the present invention provides a method for making a composite panel, said method comprising pressure moulding a cellulose fibre mass so as to form a fibre board defining a plurality of through openings or open cavities therein, covering at least one side surface of the fibre board with a cover sheet or plate, and connecting the cover sheet or plate to the side surface of the fibre board.
The openings or cavities formed in the fibre board substantially reduce the amount of cellulose fibre mass needed for producing the board and also substantially reduce the total weight of the composite panel. The openings or cavities may be shaped and arranged in a pattern such that they do not to any substantial extent reduce the strength of the composite panel.
The cellulose fibre mass may be mixed with any suitable type of adhesive or binding material, such as a resinous material, so that the fibre mass may be formed into a coherent strong body during the pressure moulding process.
The fibre mass may be made from any suitable plant material, such as straw. Preferably, however, cellulose fibre mass is a wooden fibre mass, and such mass is preferably formed into a medium density fibre board, which is well known as an mdf fibre board.
The openings or cavities formed in the fibre board may have any suitable shape and may be arranged in any suitable pattern imparting a sufficient strength to the fibre
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board. Thus, the openings or cavities in the fibre board may be shaped and arranged so as to form a grid-like structure. This grid-like structure may advantageously be formed by ribs or fins extending uninterrupted and preferably substantially linearly in the plane of the fibre board. As an example, each of the openings or cavities formed in the fibre board may have a triangular, a quadrangular, or a hexagonal outline.
A composite panel made by the method according to the invention may be formed for use as a table top or a similar supporting plate. Such table top is usually supported by legs or a frame part at least at three mutually spaced supporting points. In the case of only three supporting points, the triangular outline of the openings or cavities is preferred, while cavities or openings with a quadrangular outline may be used when the table top is supported at least at four mutually spaced supporting points.
At least the side surface or surfaces of the composite panel being visible during normal use may be provided with a cover sheet or plate whereby openings or cavities in such surfaces are being covered. This may, however, also be obtained by arranging a pair of fibre boards each having open cavities formed in a first side surface thereof with said first side surfaces in abutting engagement and by interconnecting said first side surfaces, the cover sheet or plate being connected to at least one second side surface opposite to one of said first side surfaces. In this manner the open cavities formed in the boards are converted into inner, closed cavities in the combined boards.
The cover sheet or plate may be made from any suitable conventional material having desired surface characteristics, such as veneer or plastics material.
The present invention also provides a composite panel comprising a board made from pressure moulded cellulose fibres and having a plurality of cavities formed therein, and cover sheet or plate being bonded to at least one side surface of the board, which is preferably a medium density fibre board.
The invention will now be further described with reference to the drawings, wherein Fig. 1 is a sectional view showing a part of a mould for moulding a fibre board, Fig. 2 is a fragmentary sectional view of a composite panel comprising a fibre board of the type formed in the mould shown in Fig. 1 ,
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Fig. 3 is a fragmentary plane view of a fibre board with an array of triangular cavities, Fig. 4 is a fragmentary plane view of a fibre board having quadrangular cavities formed therein,
Fig. 5 is a fragmentary plane view of fibre board having openings or cavities with an hexagonal outline, and
Fig. 6 is a fragmentary sectional view of a laminate comprising a pair of inner fibre boards and a pair of opposite outer cover plates or sheets.
Fig. 1 diagrammatically illustrates pressure moulding of a mass 10 of the type conventionally used for making mdf (medium density fibers) boards. The mass 1 0 is pressure moulded in a mould 1 1 having a lower mould part 1 2 and an upper mould part 1 3. As indicated by an arrow 14 the mould parts 1 2 and 1 3 may be moved vertically in relation to each other between an open position (not shown) and a closed position which is shown in Fig. 1 . A suitable amount of the mass 10 may be feed to and distributed on the upper surface of the lower mould part 1 2 while the mould 1 1 is in its open position. Thereafter the mould parts 1 2 and 1 3 may be moved towards each other so as to pressure mould the mass 10 into an mdf board. As shown in Fig. 1 a plurality of projections 1 5 arranged in a predetermined array extend from the upper surface of the upper form part 1 2 for forming an array of open cavities 1 6 in the adjacent surface of the fibre board 1 7 being moulded.
Fig. 2 is a sectional view of a fibre board which may be formed in a mould as that illustrated in Fig. 1 . The fibre board 1 7 defines a plane side surface 1 8 which has been covered by a thin cover sheet or plate 1 9 which may, for example, be made from veneer or plastic material having desired surface characteristics. The cover sheet 1 9 may be bonded to the fibre board 17 by a suitable adhesive or glue. The laminate or composite panel 20 thus formed may be used as a table top, and if desired also the lower surface of the table top 20 in which the cavities 1 6 are formed may be covered by a cover plate or sheet, not shown.
The opening of the cavities 1 6 may have any desired outline and may be arranged so as to form any desired pattern. Figs. 3-4 illustrate examples of such contours and arrays. In Fig. 3 the openings of the cavities 1 6 have a contour substantially defining an equilateral triangle, and the sides of each triangular opening is defined by fins or
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ribs 21 extending substantially rectilinear across the respective side surface of the board 1 7.
In the embodiment shown in Fig. 4 the fins of ribs 22 form a square grid defining square openings of the cavities 1 6 therebetween.
Fig. 5 illustrates an embodiment having fins or ribs 23 which define hexagonal openings of the cavities 16. Fig. 6 illustrates a laminate or a composite panel 24 comprising a pair of fibre board 1 7 of the type shown in Fig. 5 and a pair of cover sheets or plates forming the outer surfaces of the laminate. The side surfaces of the fibre boards having the cavities 1 6 formed therein are arranged in abutting engagement and interconnected by an adhesive or a glue such that the open cavities 1 6 of the board 1 7 together defines closed cavities or cells 26 within the laminate. The outer cover sheets or plates 25 may, for example, be made from veneer or plastics material or any other material having the desired surface characteristics.
Because of the inner cavities or cells 26 the composite panel or laminate 24 shown in Fig. 6 has a substantially reduced weight while the strength of the panel has not been reduced substantially compared with a similar solid panel. A panel of this type may, for example, be used for table tops, doors, and the like.