WO2005105433A1 - A timber substitute - Google Patents

A timber substitute Download PDF

Info

Publication number
WO2005105433A1
WO2005105433A1 PCT/AU2005/000617 AU2005000617W WO2005105433A1 WO 2005105433 A1 WO2005105433 A1 WO 2005105433A1 AU 2005000617 W AU2005000617 W AU 2005000617W WO 2005105433 A1 WO2005105433 A1 WO 2005105433A1
Authority
WO
WIPO (PCT)
Prior art keywords
layer
timber
decorative
substitute according
substitute
Prior art date
Application number
PCT/AU2005/000617
Other languages
French (fr)
Inventor
Frank Matich
Original Assignee
Armacel Pty Limited
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
Priority claimed from AU2004902304A external-priority patent/AU2004902304A0/en
Application filed by Armacel Pty Limited filed Critical Armacel Pty Limited
Publication of WO2005105433A1 publication Critical patent/WO2005105433A1/en

Links

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
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/10—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material
    • B32B3/12—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material characterised by a layer of regularly- arranged cells, e.g. a honeycomb structure
    • 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
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
    • B32B3/28—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by a layer comprising a deformed thin sheet, i.e. the layer having its entire thickness deformed out of the plane, e.g. corrugated, crumpled
    • 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
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B15/08—Layered products comprising a layer of metal comprising metal 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
    • 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
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B15/10—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of wood
    • 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
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/20—Layered products comprising a layer of metal comprising aluminium or copper
    • 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
    • B32B21/06—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 paper or cardboard
    • 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
    • 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
    • B32B21/14—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood board or veneer
    • 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
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • 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
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • 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
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
    • 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/10—Properties of the layers or laminate having particular acoustical properties
    • B32B2307/102—Insulating
    • 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/304—Insulating
    • 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/40—Properties of the layers or laminate having particular optical properties
    • B32B2307/41—Opaque
    • 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/40—Properties of the layers or laminate having particular optical properties
    • B32B2307/414—Translucent

Definitions

  • the present invention relates to timber and like building materials constructed from a laminate of "timber".
  • Normally plywood is fabricated from timber veneer with the grain of adjacent layers being perpendicular.
  • traditional "three-ply" has three layers with the grain on the outermost layers running, say, north-south and the grain of the inner layer running east- west. Where additional strength is required further layers are added to the laminate so as to create five-ply, seven-ply, etc.
  • the thermally insulative and/or acoustically insulative properties of plywood are not materially changed by increasing the number of layers from which the plywood is formed.
  • the insulative properties of five-ply are essentially similar to those of three-ply. This substantially restricts the range of applications in which plywood can be utilised.
  • the object of the present invention is to, at least to some extent, ameliorate the abovementioned disadvantages by the provision of a plywood substitute which, in its preferred embodiment, utilises the ARMACEL process.
  • the ARMACEL process and apparatus for forming structural articles, especially from weak substrates such as polystyrene and cardboard, and articles so formed, are disclosed in the applicant's International PCT Patent Application No.
  • PCT/AU95/00100 entitled "A method and apparatus for forming structural articles” (WO 95/23682), International PCT Patent Application No. PCT/AU96/00541 entitled 'Layered Structural Article” (WO 97/09166) and International PCT Patent Application No. PCT/AU00/00250 (WO 00/59709) - the contents of all three of which are hereby incorporated into the present specification by cross reference.
  • a further, specification unpublished as at the priority date of this application is that of International Patent Application No. PCT/AU2004/000826 (WO 2004/113053) which discloses the encapsulation of an interior member which is neither at least partially fluid permeable nor is perforated to become so.
  • the disclosure of that specification is also hereby incorporated by cross-reference.
  • a timber substitute comprising an outer veneer or similar decorative layer of timber and an inner thickness defining layer of thermally insulating inherently weak material, said outer layer and inner layer being at least partially encapsulated by at least one sheet of transparent thermoformable plastics material which extends over said outer layer, said transparent encapsulating layer imparting to the observable surface of said decorative layer the appearance of a treated timber finish whereby said timber substitute has a thickness determined predominately by said inner layer, a strength determined predominantly by said encapsulating layer and an appearance determined by the interaction of said encapsulating and decorative layers.
  • the substitute includes a second decorative layer located adjacent said inner thickness defining layer but on the opposite side thereof from said (firsf)decorative layer.
  • said inner thickness defining layer determines the thermally insulative and/or acoustically insulative properties of the substitute, and the inner thickness defining layer is formed from an expanded polymer. More preferably, either one or both of said decorative layers comprises a single layer veneer of timber.
  • the inner layer is an expanded polymer such as expanded polystyrene, or paper, aluminium or recycled waste materials.
  • said transparent encapsulating layer is formed from the group consisting of APET, PET, PETG, Polycarbonate, Polycarbonate/Polyester blends, ABS Polystyrene blends, HIPS Polystyrene blends, SAN Polystyrene blends, LDPE Polystyrene blends, HDPE Polystyrene blends, Polypropylene, Vinyl, PMMA Acrylic blends, Cellulose Acetate, PBT, PPE, Acetal, PVC, and NORIL.
  • a decorative sheet is interposed between the outer side of one of said decorative layers and the adjacent encapsulating layer.
  • Fig. 1 is a schematic cross-sectional view illustrating in exploded form the bringing together of an inner layer and two decorative outer layers so as to form a laminate
  • Fig. 2 is a view similar to Fig. 1 but showing the laminate in unexploded form
  • Fig. 3 shows the laminate partially encapsulated by a first transparent encapsulating layer
  • Fig. 4 shows the material of Fig. 1 inverted and encapsulated with a second transparent encapsulating layer
  • Fig. 5 is a perspective view showing the finished encapsulated plywood substitute.
  • a laminate is formed from an inner layer 3 of inherently weak material such as expanded polystyrene (EPS) and two outer layers in the form of a first outer layer 1 and a second outer layer 2.
  • EPS expanded polystyrene
  • the expanded polystyrene can be replaced with any other suitable material such as corrugated or honey-combed paper, aluminium, recycled waste materials or any other relatively low cost bulk substitute.
  • the outer layers 1, 2 are preferably formed either from a single veneer of timber or from a multi-ply timber material such as three-ply.
  • Preferably the outer surface of each of the outer layers 1, 2 has a well defined timber grain.
  • the laminate of Fig. 2 is partially encapsulated by means of the application of the above described ARMACEL process so as to form a first encapsulating layer 5. Then the article is inverted and a second encapsulating layer 6 is applied as illustrated in Fig. 4.
  • the encapsulating layers 5, 6 are formed from a thermoformable plastics material which is preferably selected from a class of materials consisting of APET, PET, PETG, Polycarbonate, Polycarbonate/Polyester blends, ABS Polystyrene blends, HIPS Polystyrene blends, SAN Polystyrene blends, LDPE Polystyrene blends, HDPE Polystyrene blends, Polypropylene, Vinyl, PMMA Acrylic blends, Cellulose Acetate, PBT, PPE, Acetal, PVC, and NORIL.
  • a thermoformable plastics material which is preferably selected from a class of materials consisting of APET, PET, PETG, Polycarbonate, Polycarbonate/Polyester blends, ABS Polystyrene blends, HIPS Polystyrene blends, SAN Polystyrene blends, LDPE Polystyrene blends, HDPE Polystyrene blends, Polypropylene,
  • the transparent encapsulating layer 5 or 6 allows the timber grain of the uppermost outer layer 1 or 2 to not only be visible but to be visible through a highly reflective surface on which reflections 8 readily form. That is, the encapsulating layer has an appearance similar to that of a highly polished varnished timber surface.
  • thermoformable plastic films such as PVC
  • embossed or indented timber pattern profile on its upper surface. This pattern is retained by the plastics material, notwithstanding that it is heated during the ARMACEL process.
  • This material enables a non-grain material, such as particle board, used as outer layer 1 to result in a grained appearance when encapsulated because the grain present on the outer surface of the encapsulating layer 5 is visible to the observer. Under these circumstances the encapsulating layer 5 need not be transparent but could be translucent or even opaque and coloured to represent a timber colour or finish.
  • the plywood substitute is of very great strength, the strength being endowed by the encapsulating layers and, in particular, by the encapsulation utilising the
  • the strength of the article is not related to the number of layers and, in particular, is very much greater than one would expect from a consideration of the individual constituents from which the finished article is fabricated.
  • the inner layer 3 very substantially increases the insulation of the finished article both in relation to heat and/or in relation to sound transmission. Indeed, a cavity or form of void can be created in the inner layer 3 to further increase the insulation values.

Landscapes

  • Life Sciences & Earth Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Wood Science & Technology (AREA)
  • Laminated Bodies (AREA)

Abstract

A plywood substitute comprises an outer veneer or similar decorative layer of timber and an inner thickness defining layer of thermally insulating inherently weak material. The outer layer and inner layer are at least partially encapsulated by at least one sheet of transparent thermoformable plastics material which extends over the outer layer. The transparent encapsulating layer imparting to the observable surface of the decorative layer the appearance of a treated timber finish. The plywood substitute has a thickness determined predominately by the inner layer, a strength determined predominantly by the encapsulating layer and an appearance determined by the interaction of the encapsulating and decorative layers.

Description

A TIMBER SUBSTITUTE Field of the Invention
The present invention relates to timber and like building materials constructed from a laminate of "timber".
Background Art
Normally plywood is fabricated from timber veneer with the grain of adjacent layers being perpendicular. For example, traditional "three-ply" has three layers with the grain on the outermost layers running, say, north-south and the grain of the inner layer running east- west. Where additional strength is required further layers are added to the laminate so as to create five-ply, seven-ply, etc.
Although the present invention is predominantly concerned with timber veneers, there are substitutes for timber formed by adhering timber particles together, such as when sawdust is adhered to form particleboard, and the like. Such timber substitutes do not normally show the attractive timber grain visible in timber veneers, however, the term "timber" as used herein is intended to cover such timber substitutes as well as timber itself.
As alluded to above, in order to strengthen plywood the traditional approach has been to increase the number of layers forming a laminate and hence the thickness and weight of the plywood increases. A characteristic of such an approach is that the strength of the plywood increases roughly in steps, each corresponding to a corresponding additional layer of the laminate.
In general, the thermally insulative and/or acoustically insulative properties of plywood are not materially changed by increasing the number of layers from which the plywood is formed. For example the insulative properties of five-ply are essentially similar to those of three-ply. This substantially restricts the range of applications in which plywood can be utilised.
Furthermore, it is traditional for plywood to be provided with a decorative finish formed by enhancing the appearance of the grain of the timber. Traditionally this has been done by applying one or more coats of clear varnish or similar clear paint finishes. Not only is such painting time consuming, but it is not particularly hard wearing and generally the varnished surface must be re-varnished after a relatively short period of time.
Object of the Invention
The object of the present invention is to, at least to some extent, ameliorate the abovementioned disadvantages by the provision of a plywood substitute which, in its preferred embodiment, utilises the ARMACEL process.
Summary of the Invention
The ARMACEL process and apparatus for forming structural articles, especially from weak substrates such as polystyrene and cardboard, and articles so formed, are disclosed in the applicant's International PCT Patent Application No.
PCT/AU95/00100 entitled "A method and apparatus for forming structural articles" (WO 95/23682), International PCT Patent Application No. PCT/AU96/00541 entitled 'Layered Structural Article" (WO 97/09166) and International PCT Patent Application No. PCT/AU00/00250 (WO 00/59709) - the contents of all three of which are hereby incorporated into the present specification by cross reference. A further, specification unpublished as at the priority date of this application is that of International Patent Application No. PCT/AU2004/000826 (WO 2004/113053) which discloses the encapsulation of an interior member which is neither at least partially fluid permeable nor is perforated to become so. The disclosure of that specification is also hereby incorporated by cross-reference.
According to an aspect of the invention there is provided a timber substitute comprising an outer veneer or similar decorative layer of timber and an inner thickness defining layer of thermally insulating inherently weak material, said outer layer and inner layer being at least partially encapsulated by at least one sheet of transparent thermoformable plastics material which extends over said outer layer, said transparent encapsulating layer imparting to the observable surface of said decorative layer the appearance of a treated timber finish whereby said timber substitute has a thickness determined predominately by said inner layer, a strength determined predominantly by said encapsulating layer and an appearance determined by the interaction of said encapsulating and decorative layers. In preferred embodiments, the substitute includes a second decorative layer located adjacent said inner thickness defining layer but on the opposite side thereof from said (firsf)decorative layer.
Preferably, said inner thickness defining layer determines the thermally insulative and/or acoustically insulative properties of the substitute, and the inner thickness defining layer is formed from an expanded polymer. More preferably, either one or both of said decorative layers comprises a single layer veneer of timber.
In preferred embodiments, the inner layer is an expanded polymer such as expanded polystyrene, or paper, aluminium or recycled waste materials.
Preferably, said transparent encapsulating layer is formed from the group consisting of APET, PET, PETG, Polycarbonate, Polycarbonate/Polyester blends, ABS Polystyrene blends, HIPS Polystyrene blends, SAN Polystyrene blends, LDPE Polystyrene blends, HDPE Polystyrene blends, Polypropylene, Vinyl, PMMA Acrylic blends, Cellulose Acetate, PBT, PPE, Acetal, PVC, and NORIL.
In preferred embodiments, a decorative sheet is interposed between the outer side of one of said decorative layers and the adjacent encapsulating layer.
Brief Description of the Drawings
Preferred embodiments of the present invention will now be described with reference to the drawings in which: Fig. 1 is a schematic cross-sectional view illustrating in exploded form the bringing together of an inner layer and two decorative outer layers so as to form a laminate,
Fig. 2 is a view similar to Fig. 1 but showing the laminate in unexploded form,
Fig. 3 shows the laminate partially encapsulated by a first transparent encapsulating layer,
Fig. 4 shows the material of Fig. 1 inverted and encapsulated with a second transparent encapsulating layer, and Fig. 5 is a perspective view showing the finished encapsulated plywood substitute.
Detailed Description
As seen in Figs. 1 and 2, a laminate is formed from an inner layer 3 of inherently weak material such as expanded polystyrene (EPS) and two outer layers in the form of a first outer layer 1 and a second outer layer 2. However, it will be appreciated that the expanded polystyrene can be replaced with any other suitable material such as corrugated or honey-combed paper, aluminium, recycled waste materials or any other relatively low cost bulk substitute.
The outer layers 1, 2 are preferably formed either from a single veneer of timber or from a multi-ply timber material such as three-ply. Preferably the outer surface of each of the outer layers 1, 2 has a well defined timber grain.
As seen in Fig. 3 the laminate of Fig. 2 is partially encapsulated by means of the application of the above described ARMACEL process so as to form a first encapsulating layer 5. Then the article is inverted and a second encapsulating layer 6 is applied as illustrated in Fig. 4. The encapsulating layers 5, 6 are formed from a thermoformable plastics material which is preferably selected from a class of materials consisting of APET, PET, PETG, Polycarbonate, Polycarbonate/Polyester blends, ABS Polystyrene blends, HIPS Polystyrene blends, SAN Polystyrene blends, LDPE Polystyrene blends, HDPE Polystyrene blends, Polypropylene, Vinyl, PMMA Acrylic blends, Cellulose Acetate, PBT, PPE, Acetal, PVC, and NORIL.
The final result is illustrated in perspective view in Fig. 5 from which it can be seen that the transparent encapsulating layer 5 or 6 allows the timber grain of the uppermost outer layer 1 or 2 to not only be visible but to be visible through a highly reflective surface on which reflections 8 readily form. That is, the encapsulating layer has an appearance similar to that of a highly polished varnished timber surface.
The above described embodiment can be modified in various ways. Firstly, rather than use plywood for the intended visible outer layer 1 (and the other outer layer 2 is desired) instead particle board, or similar, can be used. In order to achieve the desired timber grain finish, a layer of paper onto which is printed a timber grain pattern is located on the exterior surface of the outer layer 1, immediately prior to its being encapsulated by the layer 5 (as indicated in Fig. 3). Thus the timber grain visible through the transparent layer 5 is the grain of the paper sheet.
In a still further embodiment, it is known to provide some thermoformable plastic films, such as PVC, with an embossed or indented timber pattern profile on its upper surface. This pattern is retained by the plastics material, notwithstanding that it is heated during the ARMACEL process. This material enables a non-grain material, such as particle board, used as outer layer 1 to result in a grained appearance when encapsulated because the grain present on the outer surface of the encapsulating layer 5 is visible to the observer. Under these circumstances the encapsulating layer 5 need not be transparent but could be translucent or even opaque and coloured to represent a timber colour or finish.
A number of very desirable advantages flow from the above described procedures. Firstly, the plywood substitute is of very great strength, the strength being endowed by the encapsulating layers and, in particular, by the encapsulation utilising the
ARMACEL process. Thus, in general, the strength of the article is not related to the number of layers and, in particular, is very much greater than one would expect from a consideration of the individual constituents from which the finished article is fabricated.
Secondly, the inner layer 3 very substantially increases the insulation of the finished article both in relation to heat and/or in relation to sound transmission. Indeed, a cavity or form of void can be created in the inner layer 3 to further increase the insulation values.
Thirdly, an exterior surface is achieved which is akin to that of a varnished timber surface, however, the durability of the surface is very much greater than that of varnished timber and, in practice, never needs to be replaced or re-coated. In addition, the surface of the encapsulating layers also very substantially resist scuffing, scratching, marking, and the like. The foregoing describes only one embodiment of the present invention and modifications, obvious to those skilled in the art, can be made thereto without departing from the scope of the present invention.
The term "comprising" (and its grammatical variations) as used herein is used in the inclusive sense of "having" or "including" and not in the exclusive sense of "consisting only of.

Claims

1. A timber substitute comprising an outer veneer or similar decorative layer of timber and an inner thickness defining layer of thermally insulating inherently weak material, said outer layer and inner layer being at least partially encapsulated by at least one sheet of transparent thermoformable plastics material which extends over said outer layer, said transparent encapsulating layer imparting to the observable surface of said decorative layer the appearance of a treated timber finish whereby said timber substitute has a thickness determined predominately by said inner layer, a strength determined predominantly by said encapsulating layer and an appearance determined by the interaction of said encapsulating and decorative layers.
2. The substitute according to claim 1 and including a second decorative layer located adjacent said inner thickness defining layer but on the opposite side thereof from said (first)decorative layer.
3. The substitute according to claim 1 or 2 wherein said inner thickness defining layer determines the thermally insulative and/or acoustically insulative properties of the substitute.
4. The substitute according to claim 3 wherein said inner thickness defining layer is formed from an expanded polymer.
5. The substitute according to claim 4 wherein said expanded polymer is expanded polystyrene.
6. The substitute according to claim 3 wherein said inner thickness defining layer is selected from the group consisting of paper including corrugated paper and honeycombed paper, aluminium, and recycled waste materials.
7. The substitute according to any one of claims 1 to 6 wherein either one or both of said decorative layers comprises a single layer veneer of timber.
8. The substitute according to any one of claims 1 to 6 wherein either one or both of said decorative layers complies a multi-ply laminate formed from timber veneers.
9. The substitute according to any one of claims 1 to 8 wherein said transparent encapsulating layer is formed from the group consisting of APET, PET, PETG, Polycarbonate, Polycarbonate/Polyester blends, ABS Polystyrene blends, HIPS Polystyrene blends, SAN Polystyrene blends, LDPE Polystyrene blends, HDPE Polystyrene blends, Polypropylene, Vinyl, PMMA Acrylic blends, Cellulose Acetate, PBT, PPE, Acetal, PVC, and NORIL.
10. The substitute according to any one of claims 1 to 9 wherein a decorative sheet is interposed between the outer side of one of said decorative layers and the adjacent encapsulating layer.
11. The substitute according to claim 10 wherein said decorative sheet comprises paper.
12. The substitute according to any one of claims 1 to 11 wherein at least one of said encapsulating layers has formed on the inner and outer surface thereof a decorative pattern.
13. The substitute according to claim 12 wherein said patterned encapsulating layer is translucent or opaque.
14. The substitute according to any one of claims 1 to 13 wherein said inner layer includes a cavity or void to increase the insulation thereof.
PCT/AU2005/000617 2004-04-30 2005-04-29 A timber substitute WO2005105433A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
AU2004902304 2004-04-30
AU2004902304A AU2004902304A0 (en) 2004-04-30 A plywood substitute

Publications (1)

Publication Number Publication Date
WO2005105433A1 true WO2005105433A1 (en) 2005-11-10

Family

ID=35241516

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/AU2005/000617 WO2005105433A1 (en) 2004-04-30 2005-04-29 A timber substitute

Country Status (1)

Country Link
WO (1) WO2005105433A1 (en)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2498717A (en) * 2012-01-23 2013-07-31 Protomax Plastics Ltd Constructional panel with continuous polystyrene skin

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CH585323A5 (en) * 1975-04-07 1977-02-28 Keller & Co Ag Structural panel of wood particle board - covered by veneer layersand transparent thermosetting or thermoplastic foil
WO1997009166A1 (en) * 1995-09-01 1997-03-13 Armacel Pty. Limited Layered structural articles
US5702558A (en) * 1996-06-27 1997-12-30 Atlantic Automotive Components, Inc. Method of top-coating a veneered substrate
JP2001132156A (en) * 1999-10-29 2001-05-15 Kinya Sakai Composite plywood for construction

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CH585323A5 (en) * 1975-04-07 1977-02-28 Keller & Co Ag Structural panel of wood particle board - covered by veneer layersand transparent thermosetting or thermoplastic foil
WO1997009166A1 (en) * 1995-09-01 1997-03-13 Armacel Pty. Limited Layered structural articles
US5702558A (en) * 1996-06-27 1997-12-30 Atlantic Automotive Components, Inc. Method of top-coating a veneered substrate
JP2001132156A (en) * 1999-10-29 2001-05-15 Kinya Sakai Composite plywood for construction

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
PATENT ABSTRACTS OF JAPAN 15 May 2001 (2001-05-15) *

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2498717A (en) * 2012-01-23 2013-07-31 Protomax Plastics Ltd Constructional panel with continuous polystyrene skin
GB2498717B (en) * 2012-01-23 2014-06-25 Protomax Plastics Ltd Large format polystyrene panel

Similar Documents

Publication Publication Date Title
KR101956338B1 (en) Embossed and Hot-Melt Laminated Multi-Layered Composite Film
US8474208B2 (en) Floor panel containing a polymer and cork
EP0853544B1 (en) Layered structural articles
US5750240A (en) Coating of surfaces of articles
JP3105213B2 (en) Extruded heterogeneous solid surface composites and methods of making and using the same.
US20070166532A1 (en) System for use in a polymeric formulation
JP2007268843A (en) Printed matter
KR20130136373A (en) Thin floor tiles
KR200440526Y1 (en) decoration panel use for interior
JP2019511970A (en) Decorative plate, method of using the same, method of manufacturing the same, laminate containing the same, floor finish
US5919575A (en) Plastic laminated structural board and method for making same
KR20110101857A (en) Decoration sheet and process for fabricating thereof
WO2005105433A1 (en) A timber substitute
JPH11240091A (en) Decorative sheet and transfer sheet
US20020168535A1 (en) Mono- and co-extruded paper film for temporaneously or permanently protecting surfaces
CN204566852U (en) Comprise the furniture film of the trilamellar membrane of coextrusion
US20060251864A1 (en) Structural laminate
JPH04128041A (en) Decorative sheet and manufacture thereof
TW467830B (en) Magnetic susceptible markerboard
KR20080077844A (en) Syynthetic resin laminaion sheet having improved flame-reatardant and durability, and method for manufacturing the same
KR100882806B1 (en) The stripes decoration which uses the plywood it sold and his manufacturing method
KR0153076B1 (en) Sandwich panel
JP5109317B2 (en) Sheet for insert molding
JPH04128037A (en) Decorative sheet and decorative material
JP2015511134A (en) Large format polystyrene panel

Legal Events

Date Code Title Description
AK Designated states

Kind code of ref document: A1

Designated state(s): AE AG AL AM AT AU AZ BA BB BG BR BW BY BZ CA CH CN CO CR CU CZ DE DK DM DZ EC EE EG ES FI GB GD GE GH GM HR HU ID IL IN IS JP KE KG KM KP KR KZ LC LK LR LS LT LU LV MA MD MG MK MN MW MX MZ NA NI NO NZ OM PG PH PL PT RO RU SC SD SE SG SK SL SM SY TJ TM TN TR TT TZ UA UG US UZ VC VN YU ZA ZM ZW

AL Designated countries for regional patents

Kind code of ref document: A1

Designated state(s): BW GH GM KE LS MW MZ NA SD SL SZ TZ UG ZM ZW AM AZ BY KG KZ MD RU TJ TM AT BE BG CH CY CZ DE DK EE ES FI FR GB GR HU IE IS IT LT LU MC NL PL PT RO SE SI SK TR BF BJ CF CG CI CM GA GN GQ GW ML MR NE SN TD TG

121 Ep: the epo has been informed by wipo that ep was designated in this application
NENP Non-entry into the national phase

Ref country code: DE

WWW Wipo information: withdrawn in national office

Country of ref document: DE

122 Ep: pct application non-entry in european phase