SOKKA, Kasperi (Survontie 38 D 10, Jyväskylä, FI-40520, FI)
| CLAIMS 1. A composite panel, c h a r a c t e r i z e d in that the composite panel comprises more than one wood-based material layer (1, 3) and at least two functional layers (2, 4, 5), and that in at least one space between two wood-based material layers is arranged at least one functional layer (2, 4, 5), and that the functional layer (2, 4, 5) is selected from the following group: a sound-proof layer, a thermal in- sulation layer, a moisture-barrier layer, a reinforcement layer, and a flame-proof layer, and combinations thereof, and that the layers (1,2,3,4,5) are stacked one upon the other in a predetermined order, and between the layers are arranged layers of adhesive (6) in order to attach the layers to each other, and the layers are compressed together by using a single compression. 2. The composite panel according to Claim 1, c h a r a c t e r i z e d in that at least one functional layer is arranged onto the surface of the composite panel in order to form a surface layer (7) . 3. A composite panel according to Claim 1 or 2, c h a r a c t e r i z e d in that more than one functional layer (2, 4, 5) is arranged between two layers of wood-based material (1 , 3 ) . 4. A composite panel according to any of the Claims 1-3, c h a r a c t e r i z e d in that at least one functional layer (2, 4, 5) is arranged in more than one space between the layers of wood-based material (1, 3) . 5. A composite panel according to any of the Claims 1-4, c h a r a c t e r i z e d in that at least one reinforcement layer is arranged as a functional layer (2, 4, 5) between two layers of wood-based material (1, 3) . 6. A composite panel according to any of the Claims 1-5, c h a r a c t e r i z e d in that the functional layer (2, 4, 5, 7) is a fibre reinforcement layer. 7. A composite panel according to any of the Claims 1-6, c h a r a c t e r i z e d in that the functional layer (2, 4, 5, 7) is a cellular board. 8. A composite panel according to any of the Claims 1-7, c h a r a c t e r i z e d in that the functional layer (2, 4, 5, 7) is a layer of insulation material. 9. A composite panel according to any of the Claims 1-8, c h a r a c t e r i z e d in that the functional layer (2, 4, 5, 7) is formed of polymer-based material. 10. A composite panel according to any of the Claims 1-9, c h a r a c t e r i z e d in that the functional layer (2, 4, 5, 7) is formed of metal-based material. 11. A composite panel according to any of the Claims 1-10, c h a r a c t e r i z e d in that a ballistic layer is arranged as a functional layer (2, 4, 5, 7) together with the composite panel. 12. A method of producing a composite panel according to any of the Claims 1-11, c h a r a c t e r i z e d in that more than one layer of wood-based material and at least two functional layers are stacked one upon the other, and that at least one functional layer is arranged in at least one space between two wood-based layers, and that the functional layer is selected from the following group: a sound-proof layer, a thermal insulation layer, a moisture-barrier layer, a rein- forcement layer, and a flame-proof layer, and combinations thereof, and that layers of glue are arranged between the layers in order to attach the layers to each other, and the layers are compressed together by using a single compression. 13. The method according to Claim 12, c h a r a c t e r i z e d in that at least one functional layer is arranged onto the surface of the composite panel in order to form a surface layer. 14. A method according to Claim 12 or 13, c h a r a c t e r i z e d in that more than one functional layer is arranged between two layers of wood-based material . 15. A method according to any of the Claims 12-14, c h a r a c t e r i z e d in that at least one functional layer is arranged in more than one space between two layers of wood-based material. 16. Use of a composite panel according to any of the Claims 1- 11, c h a r a c t e r i z e d in that the composite panel is used as building material and/or as protective material . |
FIELD OF THE INVENTION The present invention relates to a composite panel, which is specified in the preamble of Claim 1, and a method of producing the composite panel, which method is specified in the preamble of Claim 12, and the use of the composite panel, which use is specified in the preamble of Claim 16.
BACKGROUND TO THE INVENTION
Different composite panels or compound boards are already known, and these boards are made by combining wood-based ma- terial and at least one other material. In the production of composite panels, it is an aim to maximise the useful properties of the materials and to minimise the weaknesses . Previously, one known way to make composite panels was to mix various raw materials with each other in order to construct the composite panel. It is also known that composite panels are made by coating for example a wooden board with different materials .
Also previously known is that various compression methods are employed in the production of different boards.
PURPOSE OF THE PRESENT INVENTION
It is a purpose of the present invention to provide a novel composite panel which combines a range of properties that are consistent with the purpose for which that board will be used. SUMMARY OF THE PRESENT INVENTION
The composite panel and the method of producing it and using it, according to the present invention, are mainly characte- rized by what is stated in the claims.
The present invention is based on a composite panel which is formed of layers of a wood-based material and at least one layer of another material. The composite panel according to the present invention is comprised of more than one layer of a wood-based material and at least two functional layers, and at least one functional layer is arranged in at least one space between two layers of wood-based materials, and the functional layer is chosen from the following group: a sound- proof layer, a thermal insulation layer, a moisture-barrier layer, a reinforcement layer, and a flame-proof layer, and combinations thereof. The layers are stacked one upon the other in a predetermined order, layers of adhesive are arranged between the layers in order to attach the layers to each other, and the layers are compressed together by using a single compression in order to form a composite panel.
In the present context, composite panel means any compound board which is formed by layers which are formed of a wood- based material, and at least one layer of another material.
In the present context, wood-based material means any material which is formed of wood material or wood fibre materials, for example wood veneer such as softwood or hardwood veneer, or multilayer board, plywood or wooden board or similar wood- based material. In one embodiment, the thickness of the wood veneer may vary. In an embodiment, the thickness of the wood veneer ranges between 0.5 and 6 mm. In another embodiment, the wood veneer is generated by lathing, cutting or sawing.
In the present context, adhesive layer means an intermediate layer, the purpose of which is to attach layers of different materials to each other, and which is formed of any adhesive that is known per se, for instance resin, phenol-formaldehyde glue, melamine-formaldehyde glue, urea-formaldehyde glue and/or polyurethane glue or other adhesive which is suitable for the purpose.
In the present context, single compression means a method in which all the desired component layers, i.e. material layers and adhesive layers, are stacked at the same time to form a blank, and the board is generated in one compression stage.
In one embodiment of the present invention, at least one functional layer is arranged onto the surface of the composite panel in order to form a surface layer. In one embodiment of the present invention, more than one functional layer is arranged between two layers of wood-based material. In one embodiment, at least two functional layers are placed between layers of wood-based material. In another embodiment, at least three functional layers are placed be- tween layers of wood-based material. In another embodiment, at least four functional layers are placed between layers of wood-based material. Alternatively, one functional layer is arranged between two layers of wood-based material . In one embodiment of the present invention, at least one functional layer is arranged in more than one of the spaces between two layers of wood-based material. In one embodiment of the present invention, at least one reinforcement layer is arranged, as a functional layer, between two layers of wood-based material . In one embodiment of the present invention, the functional layer is a fibre reinforcement layer. In another embodiment, the fibre reinforcement layer is formed of fibre-based material. In one embodiment of the present invention, the functional layer is a cellular board. The cellular board advantageously lightens the structure. The cellular board can be any cellular material which is suitable for the purpose of use and which is known per se.
In one embodiment of the present invention, the functional layer is a layer of insulating material .
In one embodiment of the present invention, the functional layer is formed of polymer-based material. In another embodiment, the polymer-based material can preferably comprise polyethylene, polypropylene, polyamide, aramid, carbon fibre, resin, cellulose, cellulose ester, cellulose ether, viscose fibre, cuprous fibre, modal fibre or other polymer or plastic, which are suitable for the purpose, or different combinations thereof .
In one embodiment of the present invention, the functional layer is formed of metal-based material.
In one embodiment, the fibre-based material can comprise natural fibres, such as plant fibres for example seed floes such as cotton, stalk fibres such as flax, leaf fibres such as sis- al or fruit fibres such as cocos; or animal fibres such as keratin for example wool, or gland secretion for example silk; or mineral fibres, such as asbestos; or artificial fibres such as regenerated fibres, for example viscose, modal, cupro or lyocell, or cellulose acetate, for example acetate or triacetate; or synthetic fibres, such as polyamide, acryl, polyester, chlorofibre, polypropylene or elastane; or inorganic fibres such as glass, metal or rubber, or different combinations of any of the above.
In one embodiment, the functional layer is formed of polymer- based material, fibre-based material, metal-based material or different combinations thereof. In one embodiment, the sound-proof layer is formed of cellular board, fibre-based material, polyurethane insulation material, cork material, cork composite material or other sound-proof material which is suitable for the purpose of use. In one embodiment, the thermal insulation layer is formed of cellular board, fibre-based material, polyurethane insulation material, cork material, cork composite material or other thermal insulation material which is suitable for the purpose of use.
In one embodiment, the reinforcement layer is formed of polyester-based material, fibre-based material, glass, basalt, carbon, asbestos, wollastonite, silicates, or different combinations thereof. In one embodiment, the reinforcement layer is formed essentially together with the layer of glue, for instance by arranging a suitable reinforcement material or suitable reinforcement fibres into the glue layer, or by impregnating the reinforcement layer with an adhesive, in which case a combined layer of glue and reinforcement is advantageously generated.
In one embodiment, the moisture-barrier layer is formed of po- lymer-based material, which can be any polymer or plastic based material which is suitable for the purpose of use, for instance one of the polymer-based materials listed above.
In one embodiment, the flame-proof layer is formed metal-based material, for instance aluminum film, or other flame-proof material which is suitable for the purpose of use.
In one embodiment of the present invention, at least one ballistic layer is arranged as a functional layer together with the composite panel. In one embodiment, the surface layer is a ballistic layer, preferably a ballistic shield layer. In one embodiment, the ballistic layer is arranged between layers of wood-based material. In one embodiment, the ballistic layer is formed of metallic material, metal-based material, or rock, mineral or ceramic based material, or different combinations thereof, and the ballistic layer can be in a platelike, boardlike or filmlike form, depending on the application. In one embodiment, it is also possible to create the ballistic layer of fibres which possess ballistic properties, or other mate- rials which possess ballistic properties. In one embodiment, material which possesses ballistic properties, for instance fibres or ceramic plate material, can be arranged in conjunction with another functional layer to form compound layers, the properties of which vary. Here, ballistic shield means protection against flying objects, preferably splinters or bullets .
In one embodiment, the surface layer can be a reinforcement layer, a moisture-barrier layer, a flame-proof layer, an insulation material layer, or a combination of different layers . Furthermore, the present invention is based on a method of producing any of the composite panels described above.
According to the present invention, more than one layer of wood-based material and at least two functional layers are stacked one upon the other, and at least one functional layer is arranged in the space between two wood-based layers, and the functional layer is chosen from the group the following group: a sound-proof layer, a thermal insulation layer, a moisture-barrier layer, a reinforcement layer, and a flameproof layer, and combinations thereof, and layers of glue are arranged between the layers in order to attach the layers to each other, and the layers are compressed together by using single compression.
It is possible to coat the composite panel with any suitable coating.
Furthermore, the present invention is based on the use of any of the composite panels described above as building material and/or protective material, such as thermal insulation ma- terial, sound-proof material, moisture-barrier material, door material or flame-proof material, or as a protective board, such as a ballistic shield or a similar shield.
In one embodiment, the composite panel can be used as floor, wall or ceiling material in permanent or temporary solutions outdoors and indoors. In addition, it is possible to use a composite panel as base material of a floor, for instance as a base plate of parquet floors or laminate floors. Considerable advantages are achieved with a composite panel according to the present invention, compared with the known technology. A composite panel according to the present invention is a strong, light and durable board structure.
A versatile composite panel which combines many properties is achieved with the present invention. A composite panel according to the present invention enables, for instance, simultaneous thermal insulation, sound-proof, moisture- barrier, reinforcement and flame-proof properties, and ballistic protection of the board material. Thanks to the present invention, a single board serves several simultaneous purposes in the same application.
LIST OF FIGURES Figure 1 is a simplified diagram of a composite panel according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION In the following, the present invention is described with the help of a detailed example of an application, and reference to the accompanying figure 1.
The composite panel shown in figure 1 is intended to be used simultaneously both as a building material and a protective material, such as thermal insulation material, sound-proof material, moisture-barrier material and flame-proof material. It is possible to use the composite panel as, for instance, a ballistic shield or as a door material, or floor, wall or ceiling material.
In the composite panel shown in figure 1, it is possible to use wood-based veneers which are known per se as wood-based material (1, 3)
The composite panel in figure 1 comprises a first wood-based veneer layer (1), three different functional layers (2, 4, 5) and a second wood-based veneer layer (3) . The functional layers (2, 4, 5) are placed between the layers of veneer (1, 3) . The functional layers of the composite material comprise two reinforcement layers (2) , and a cellular board layer (4) and an aluminum film layer (5) which are arranged between them. The reinforcement layers (2) are formed of natural fibres and/or synthetic fibres or staple fibres thereof. Onto the outer surface of the first wood-based veneer layer (1) of the composite panel a surface layer (7) is arranged as a ballistic shield layer, which is formed of a ceramic plate. All the material layers (1, 2, 3, 4, 5) are attached to each other by layers of glue (6), which comprise an adhesive which is suitable for the application.
The composite panel according to the present invention is suitable to be used as different embodiments in a great variety of applications .
The present invention is not limited to apply only to the example described above, rather many variations are possible as long as the principle of the invention specified by the claims is not infringed.