COMPOSITE STRUCTURAL COMPONENT AND METHOD OF MAKING SAME

COMPOSANTE STRUCTURALE EN COMPOSITE ET METHODE DE FABRICATION ASSOCIEE

English Abstract

ABSTRACT
A composite includes a board. The board includes: a pair of corrugated layers,
each
corrugated layer being formed from two corrugated sheets bonded together; and
a
cardboard honeycomb layer disposed between and bonded to the corrugated
layers,
the honeycomb layer being orientated such that the cells extend between the
corrugated layers. The board can be cut using conventional machinery without
fraying ,
thereby requiring little or no sanding, and can be edgetaped without being
crushed
using conventional edge taping machinery.
Date Recue/Date Received 2022-04-20

French Abstract

ABRÉGÉ Une structure composite qui comprend un panneau. Le panneau comprend : une paire de couches ondulées, chaque couche étant formée de deux tôles ondulées liées et une couche de carton en nid d'abeille placée entre les tôles liées et fixée à ces dernières et orientée pour que les cellules sétendent entre les couches ondulées. Le panneau peut être coupé au moyen déquipement classique sans usure, ce qui nécessite peu ou pas de sablage, et du ruban adhésif peut être utilisé sans lécraser au moyen doutils dapplication de ruban adhésif traditionnels. Date reçue/Date Received 2022-04-20

Claims

CLAIMS
1. A composite comprising:
a board including
a pair of corrugated layers, each of the pair of corrugated layers being
formed from two corrugated sheets bonded together;
a cardboard honeycomb layer disposed between and bonded to the pair of
corrugated layers, the honeycomb layer being orientated such that the
cells extend between the pair of corrugated layers.
2. The composite according to claim 1, wherein the pair of corrugated
layers are
bonded to the honeycomb layer by PVA glue.
3. The composite according to claim 1, wherein each of the pair of
corrugated
layers comprises a pair of B flute layers bonded together and a pair of E
flute
layers each bonded to one of the B flute layers.
4. The composite according to claim 3, wherein the E and B flute layers are

bonded together with PVA glue.
5. The composite according to claim 3, wherein the E flute layer has a
thickness
of approximately 0.06" and the B flute layer has a thickness of approximately
0.11".
6. The composite according to claim 3, wherein the board further comprises,
for
each of the pair of corrugated layers, a backer layer overlying and bonded to
said each of the pair of corrugated layers.
7. The composite according to claim 6, wherein each backer layer is formed
from Polybak B90, with a thickness of .026", and is bonded to the adjacent
corrugated layer with PVA glue.
Date Recue/Date Received 2022-1 0-1 9

8. The composite according to claim 6, wherein the board further comprises,
for
each backer layer, a cover layer overlying and bonded to said each backer
layer.
9. The composite according to claim 8, wherein the cover layer is a matte
Renolit vinyl with a thickness of 0.008" bonded to said each backer layer with

PVA glue.
10. The composite according to claim 2, further comprising an edge band
surrounding the edge of the board.
11. The composite according to claim 10, wherein the edge band is PVC and
is
bonded to the board using PUR glue.
6
Date Recue/Date Received 2022-10-19

Description

CA 02924333 2016-03-21
COMPOSITE STRUCTURAL COMPONENT
AND METHOD OF MAKING SAME
TECHNICAL FIELD
[0001] The present disclosure relates generally to a composite structural
component.
BACKGROUND
[0002] Composite structural components including composite boards utilizing

honeycomb centers have been disclosed in the art, However, known composite
boards
suffer from an unattractive combination of: (i) relatively high processing
costs; and (ii)
relative difficulty in machining and/or edge banding it.
BRIEF DESCRIPTION OF THE DRAWINGS
[0003] FIG. 1 is a top perspective view of a finished composite component
according
to one exemplary embodiment of the invention; and
[0004] FIG. 2 is a view along 2-2 of FIG. 1.
DETAILED DESCRIPTION
[0005] A composite component 20 which forms an exemplary embodiment of the
present invention is hereinafter described with reference to FIGS. 1 and 2.
[0006] Composite component 20 will be seen to include a composite board 10 and
a
PVC edge band 11.
[0007] Composite board 10 includes a honeycomb layer 12, a pair of
corrugated
layers 14 flanking the honeycomb layer 12, a backer layer 16 overlying each
corrugated
layer and a cover layer 18 overlying each backer layer 16.
[0008] Honeycomb layer 12 shown is formed from 0.5" honeycomb sheet from Axxon

Packaging.
1

[0009] Each corrugated layer 14 is formed from two EB corrugated sheets
bonded
together and to the honeycomb layer with PVA glue. [For greater certainty,
layer 20 is
an E flute layer with a thickness of approximately 0.06" and layer 22 is a B
flute layer
with a thickness of approximately 0.111
[0010] Each backer layer 16 is formed from PolybakTM B90, with a thickness
of .026",
and is bonded to the adjacent corrugated layer 14 with PVA glue.
[0011] Each cover layer 18 is a matte RenolitTM vinyl with a thickness of
0.008"
bonded to the corrugated layer with PVA glue.
[0012] The method of making composite board 10 is described as follows:
= an EB sheet is put through a glue roller applicator to apply a layer of
adhesive
to produce a coated EB sheet and a further EB sheet is laid upon the coated
EB sheet to form an EBBE combination;
= the EBBE combination is passed through a pinch roller to form an EBBE
sheet;
= the honeycomb sheet is passed through a double roll glue applicator to
apply
adhesive on both sides of the honeycomb sheet and is laid upon an EBBE
sheet, and a further EBBE is laid upon both, to form an EBBE-honeycomb-
EBBE bundle;
= the EBBE bundle is passed through a pinch roller to produce an EBBE
sandwich and the EBBE sandwich is placed in a pneumatic pressure for 20
minutes to produce an EBBE board;
= the backer and cover layers are applied in a manner analogous to the
manner
of application of the EBBE layers; and
= the entire assembly is machined to size using a HomagTM WIKI Vantage 43
CNC cutting machine armed with the Solid Carbide UN-ruffer 67-445 (1/2"
2
Date Recue/Date Received 2022-04-20

dia) and the Solid Carbide Honeycomb Hogger.
[0013] Edge band 11 is applied using a HomagTM Edgebander and PURTM glue to

form the composite component 20.
[0014] Whereas a specific embodiment is herein shown and described,
variations
are possible. For example:
= whereas a specific cutter is mentioned, other cutters, such as table
saws,
band saws and CNC routers can be utilized;
= whereas EBBE sheets are mentioned, other combinations can be utilized,
provided that the thickness of each corrugated layer is at least about 3/8",
which allows for edge banding;
= whereas a honeycomb layer of 0.5" is mentioned, thicknesses of up to
2.25"
can be utilized;
= whereas a PVC edge band is specifically mentioned, ABS and polypropylene
can also be used;
= whereas PUR glue is taught for use in edge banding, hot-melt EVA can also

be utilized;
= whereas a pair of cover layers is shown, these are not essential;
= whereas PolyBakTM is specifically mentioned, other strong polymer
saturated
Kraft papers can be used without sacrificing machinabilit; and
= whereas RenolitTM vinyl is mentioned, other standard general purpose
laminates can be used.
3
Date Recue/Date Received 2022-04-20

[0015] Further, whereas HelmibondTM 816 is mentioned, other glues can be
used.
Advantages of using PUR glue, for example, are that it sets quickly and can
avoid or
minimize the need for pressing. However, it is important to select a glue that
hardens
and strengthens the surface. HelmibondTM 816 was found to provide a hard glass-
like
surface upon curing, which provided a board that did not require special
handling, that
cut using conventional machinery without fraying [thereby requiring little or
no sanding]
and that could be edgetaped without being crushed using conventional edge
taping
machinery.
4
Date Recue/Date Received 2022-04-20

Representative Drawing