GB2507942A

GB2507942A - Composite furniture panel having core of corrugated layers with perpendicular axes

Info

Publication number: GB2507942A
Application number: GB1209323.3A
Authority: GB
Inventors: Barry Arnold
Original assignee: COUNTRY GARDEN KITCHENS Ltd
Current assignee: COUNTRY GARDEN KITCHENS Ltd
Priority date: 2012-05-24
Filing date: 2012-05-24
Publication date: 2014-05-21
Also published as: GB201209323D0

Abstract

The core of the composite furniture panel comprises corrugated layers 1, 2. The axis of corrugation of one layer 1 is at right angle (orthogonal) to the axis of corrugation of a layer 2 to which it is bonded. Preferably, the corrugations 1, 2 are isosceles trapezoidal. The corrugated sheets 1, 2 are preferably, translucent, transparent or semi-transparent plastic, especially polyvinyl chloride (PVC). The preferred core also includes, facing layers 3, 4, a rod and edging. Preferably an extended panel is formed by bonding cores together. The panel is used in kitchen, bathroom or bedroom cabinets.

Description

Compdsité Furniture Panel the present invention relates to a composite furniture panel core and a. method of manufacturing a composite furniture panel core, S. Many conventional furniture cabinets such as kitchen, bathroom and bedroom units are made up of panels made from melamine faced particulate board. Although most particulate board is now made from sustainable wood the method of manufacture and end of life disposal still has a significant impact on the environment.

It is common for furniture panels to be made in various shapes and sizes for assembly into furniture unIts such as cabinets. Once assembled these furniture units are heavy to handle, and although meet the required standards are not completely waterproof.

Many sizes, types and configurations of cabinet are offered to cater for variations in room * size and type. The manufacturer is therefore required to produce many variations of panel size which, in turn, reduces the quantity of each pane! made. This has an impact on the method of manufacture.

In furniture construction composite panels may be used as alternatives to wooden panels, particularly where a lightweight panel is required. A composite panel is rhade of a number of elements joined together in some manner, for example' having a core with an external covering.

For example, a panel may comprise a honeycomb core sandwiched between two other layers. However1 such honeycomb core panels are only suitable where strength and * . stability are notrequired and are complex to manufacture and costly. * *

* The invention is set out in the claims. . . . * 30 *..

A panel core according to the present invention may be lightweight1 strong and stable. It :.:. may be made at least partly from recycled material and may be recycled. *

A panel core having substantially isosceles trapezoid corrugations may be particularly strong and rigid.

A transparent panel core may allow lighting effects to be applied through the panel core.

A panel according to the present invention may be structurally sound, lightweight1 strong and stable and waterproof.

Any panel core and panel layers made from PVC for example may be at least partly made from recycled material and may themselves be recycled. PVC is also an example of a waterproof méterial and a furniture cabinet comprising PVC panels for example may last substantially longer than a conventional furniture panel in situations where the cabinet is likely to get wet, for example near a kitchen sink. In properties in areas prone to flooding, such cabinets not only may survive flooding but also may be moved off the ground out of flood water due to being lightweight. Further, such a panel may be flame proof and may not support combustion.

Manufacturing of the panel core may be simple and cheap, as the core may be manufactured by extrusion. Manufacturing may also be flexible, as single and twin sheet vacuum forming may also be used to manufacture the core which, although is more complex and expensive than extrusion can be more quickly set up. For example, a manufacturing presence may be initiated using single sheet vacuum forming whilst an extrusion faci!ity is set up and then manufacturing may be continued using extrusion.

Embodiments of the present invention wil! now be described by way of example only with reference to the accompanying drawings, in which: Figure 1 is a cross section of an example composite furniture panel in accordance with the present invention; Figure 2 is a cross section at right angles to the view showh in figure 1, through the part of * figure 1 marked AA, of an example composite furniture panel in accordance with the * present invention; **..*.

Figure 3 is a diagram of an example type of corrugation of a core layer of an example *..

panel core according to the invention; Figure 4 is a cross section of an edge of an example composite furniture panel core in * accordance with the present invention; and S S * * * Figure 5 is a flow diagram of example manufacturing steps in accordance with the invention.

As can be seen in Figures 1 and 2, a furniture panel core according to an example of the invention comprises two corrugated layers 1, 2 bonded together so that the corrugation axes are at an angle of 90 degrees to each other. A facing layer 3, 4 is bonded to the outet side of each corrugated layer 1, 2 toform a panel 5.

A corrugated sheet is rigid when bent at 90 degrees to the, corrugation but bends easily with the corrugation. By bonding two sheets to each other so' that they are substantially perpendicular, rigidity is achieved in both orthogonal directions.

The corrugations may hayS a castellated form to optimize the area for bonding the two layers 1 2 together and rigidity of the layers 1, 2.

In this example, the corrugations have isosceles trapezoid cross section, with legs 6, troughs 7 and crests 8 being of substantially equal length, as can be seen in more detail in 15' Figure 3. The corrugation shown in Figure 3 has a corrugation axis at right angles to the plane of the diagram. The exact shape and structure of the core layers 1, 2, such as the depth, pitch and angle of corrugations may be designed specifically for the load and strength requirements of the finished product. For example, the corrugations may have a depth of 8mm and a pitch of 22.7mm and a leg, trough and crest length of 10mm. 20.

The core layers, 2 may be made from a plastic such as PVC or any other material known for this particular use by the skilled person. If PVC is used, this may. be, for example, 60% recycled and 40% virgin PVC or 80% recycled and 20% virgin. The core - layers I and 2 may be transparent. . -25, :.--. Figure4 shows an example edging 9 of a panel core. Each of the corrugated layers 1, 2 has an altered cross section along each edge parallel to the corrugation axis shaped to * close off a pair of edges of the panel 5 as shown in figure 4. As can be seen from figure 4, this edging 9 is formed from an extension of a leg 6 of a corrugation at an end of a corrugated layer 1, 2 and extending beyond the depth of the corrugation. The length of the edging 9 may be such that when facing layers 3, 4 are added to the panel core to make a :.. complete panel 5, the edging 9 meets a facing layerS, 4, for'example by having a length that matches the depth of the core. Thus by using corrugated layers 1, 2 each with an edging 9 at each end the panel 5 may be sealed when the core layers 1, 2 and facing 35, layers 3, 4 are all bonded together. -If an especially strong panel 5 is required, multiple panel cores may be stacked and bonded together (not shown).

An alternative or additional way to achieve an especially strong panel may be to place one or more rods within the corrugation structure parallel to the corrugation axis, that is, along the length of one or more of the corrugations (not shown). Such rods may be also be made from PVC.

Figure 5 shows an example manufacturing process. Raw material combined with ground recycled material is placed in an!niection tool 10 for me'lting and transferring to an extrusion machine 11. The extrusion machine 11 is filled with a profile mould of the corrugated layer 1, 2 required. The molten material is famed through this mould and immediately cooled. Once cool the rigid sheet is cut to size in a guillotine 12. The act of moulding and cutting to size is continuous. Two cut corrugated layers 1, 2 are then placed in a holding jig within a panel assembly tool 13. The two layers 1, 2 are mounted at right angles to each other and clamped. The holding jig is transferred to an ultrasonic welding machine 14 where the layers 1, 2 are welded together to form a panel core..

A panel facing sheet 3, 4 is placed in the bottom of an adhesive press 15 and adhesive applied to it from an adhesive dispenser 16. The core is placed on to the facing sheet 3, 4 and adhesive is placed on its top face from the adhesive dispenser 16.. A further facing sheet 4, 3 is placed on to the core and the press tool 15 closed. Pressure is applied to the assembly to ensure a fully bonded panel 5. The time the assembly is held in the mould 15 is dependent on the adhesive used and the facing sheet material. 25. .

Once bonded the panel 5 is removed and cleaned of any, adhesive runs. The panel is then placed in an edge banding machine 17 if any edging is to be applied to the panel.

* Adhesive is applied from the adhesive dispenser 16 to the panel core edges and edge pieces applied and clamped tà the panel. 30.

Once the adhesive is set the panel 5 is cleaned, and ready packed.

The inner core layers 1 and 2 are an open structure which may be formed by extrusion, single or twin sheet vacuum forming or any other suitable process known to the skilled person. , . The core layers 1, 2 may be bondèdtogèther in any suitable known manner for this particular use, such as by ultrasonic welding. Substantially flat crests 8 and troughs 7 of the corrugations as shown in figure 3 may when used as bonding areas allow for simple and strong bonding, but any suitable corrugation configuration and bonding area arrangement, including irregular configurations and arrangements maybe used.

When faced with a suitable facing material a structurally sound panel 5 may be formed.

The facing sheets 3, 4 may be made from a plastic such as PVC or any other material known for this particular. use by the skilled person. The material of the facing sheets 3, 4.

may be chosen for aesthetic purposes depending on the application of the panel. The facing sheets 3, 4 may be bonded to the core material 1, 2 in any known manner such as by welding or with appropriate adhesive to provide a secure and lasting bond between the facing material 3, 4 and core layers 1, 2. Edge pieces may also be bonded to the edges of the panel core (not shown), for example for decorative purposes.

I The formulation of any adhesive will depend on the material of the facings 3, 4 and core 1, 2 as known by the skilled person. . . The facing sheets 3.4 may be manufactured from transparent, translucent or semi-transparent material. The panel. 5 may be transparent, translucent or semi-transparent core material. Light applied internally or externally along the corrugations of the panel ma' be transmitted through the panel 5. -. *. .* . * * -. * * a.

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Claims

CLAIMS1 A composite furniture panel core comprising: first and second corrugated layers having a first and second corrugation axis respectively; wherein the first and second layers are bonded together such that the first and second corrugation axes are substantially perpendicular.
2. A panel core according to claim 1, wherein the corrugations are substantially trapezoidal. -
3. -A panel core according to claim 2, wherein the'corrugations are substantially isosceles trapezoidal.
4. A panel core according to claim 3, wherein the isosceles trapezoids have crests-trough and legs of substantially equal length.
5. A panel core according to any preceding claim, wherein the layers are translucent, semi-transparent or transparent.
6. A panel core according to any preceding claim, wherein the layers are plastic.
7. A panel core according to claim 6, wherein the plastic is PVC.* 25:
8. A panel core according to any preceding claim, the core further comprising at least one rod within at.least one corrugated layer.
9. A panel core according to any preceding claim, at least one of the corrugated * * layers comprising at least one edging formed from an extension of a leg of a corrugation at an end of a corrugated layer and extending beyond the depth of the corrugation.:.. -10. An extended panel core comprising a plurality of cores according to any preceding claim stacked and bonded together. * * /Ii. A panel comprising: * -. a panel core according to any of claims ito 9; and -7-.first and second facing layers bonded to the first and second corrugated layers respectively.12. A panel accOrding to claim 11 when dependent on claim 9, wherein the facing layers are further bonded to the at least one edging.13. An extended panel comprising: first and second facing layers; and an extended panel core according to claim 9 bOnded between the facing layers.14. A furniture cabinet comprising a panel according to any of claims 11 tol 3.15.. A methbd of manufacturing a composite panel core, the method comprising the steps of: forming first and second corrugated layers; bonding the layers together such that the first and second corrugation axes are.substantially perpendicular.16. A method accordinglo claim 15, wherein forming first and second. corrugated layers comprises forming at least one edging as an extension of a leg of a corrugation at an end of the corrugated layer and extending beyond the depth of the corrugation.17. A method according to claim 15 or daim 161 comprising forming the corrugated layers from plastic. . . . . * 18. A method according to claim 17, the plastic is PVC.* 19. A method according to any of claims 15 to 18, wherein the step of forming the panels comprises forming the panels by extrusion or single or twin sheet vacuum forming.30. . . .. .. - * 20 A method according to any of claims 15 to 19, further comprising thestep of placing one or more rods within at least one Of the cthrugated layers before bonding the corrugated layers together.****** . * * . / ( 21. A method according to any of claims 15 to 20, wherein the step of bonding the corrugated layers comprises bonding the corrugated layers using ultrasonic welding or adhesive.22. A method of manufacturing a composite panel, the method comprising the steps of any of claims 15 to 21 and further comprising the step of: bonding first and second facing layers to the first and second layers respectively.23. A method according to claim 22, wherein the step of bonding the facing layers comprises bonding the corrugated layers using ultrasonic welding or adhesive.24. A panel core substantially S described herein with reference to the accOmpanying drawings.25. A panel substantially as described herein with reference to the accompanying drawings. / * -* * * . * .S*.**** -* *S*5*S** * * * .-;_ * *S * * S *** * * -S.....-f *--. -: