Composition and method of manufacture for a fiber panel having a finishable surface

Abstract

A panel is provided having a surface layer. The surface layer includes a surface that is the exterior surface of the panel. The surface layer includes a blend of nucleated binder fibers and synthetic fibers and forms a finishable, substantially defect and porosity free surface layer based on visual inspection.

Description

BRIEF DESCRIPTION OF DRAWINGS

The patent or application file contains at least one drawing executed in color. Copies of this patent or patent application publication with color drawing(s) will be provided by the Office upon request and payment of the necessary fee.

The present disclosure will be described hereafter with reference to the attached drawings which are given as non-limiting examples only, in which:

FIG. 1 is an exploded side view of a laminated hardboard panel;

FIG. 2 is a side view of the laminated hardboard panel of FIG. 1 in an illustrative-shaped configuration;

FIG. 3 is a perspective view of a portion of the laminated hardboard panel of FIG. 1 showing partially-pealed plies of woven and non-woven material layers;

FIG. 4 is another embodiment of a laminated hardboard panel;

FIG. 5 is another embodiment of a laminated hardboard panel;

FIG. 6 is another embodiment of a laminated hardboard panel;

FIG. 7 is a perspective view of a honeycomb core laminated panel;

FIG. 8 is a top, exploded view of the honeycomb section of the panel of FIG. 7;

FIG. 9 is a perspective view of a portion of the honeycomb section of the panel of FIG. 7;

FIG. 10 is a perspective view of a truss core laminated panel;

FIG. 11 a is a side view of an illustrative hinged visor body in the open position;

FIG. 11 b is a detail view of the hinge portion of the visor body of FIG. 11a;

FIG. 12 a is a side view of an illustrative hinged visor body in the folded position;

FIG. 12 b is a detail view of the hinge portion of the visor body of FIG. 12a;

FIG. 13 is an end view of a die assembly to compression mold a fiber material body and hinge;

FIG. 14 a is a top view of the visor body of FIGS. 11 and 12 in the open position;

FIG. 14 b is an illustrative visor attachment rod;

FIG. 15 is a perspective view of a wall panel comprising a laminated panel body;

FIG. 16 is a work body;

FIG. 17 is a sectional end view of a portion of the work body of FIG. 16 showing an illustrative connection between first and second portions;

FIG. 18 is a sectional end view of a portion of the work body of FIG. 16 showing another illustrative connection between first and second portions;

FIG. 19 is a sectional end view of a portion of the work body of FIG. 16 showing another illustrative connection between first and second portions;

FIG. 20 is a side view of a hardboard manufacturing line;

FIG. 21 a is a top view of the hardboard manufacturing line of FIG. 20;

FIG. 22 is a side view of the uncoiling and mating stages of the hardboard manufacturing line of FIG. 20;

FIG. 23 is a side view of the pre-heating stage of the hardboard manufacturing line of FIG. 20;

FIG. 24 is a side view of the heat, press and cooling stages of the hardboard manufacturing line of FIG. 20;

FIG. 25 is a side view of a laminating station and shear and trim stages as well as a finishing stage of the hardboard manufacturing line of FIG. 20;

FIG. 26 is a top view of the laminating station and shear and trim stages as well as the finishing stage of the hardboard manufacturing line of FIG. 20;

FIG. 27 is a side view of a portion of the laminating station stage of the hardboard manufacturing line of FIG. 20;

FIG. 28 is another top view of the shear and trim stages as well as the finishing stage of the hardboard manufacturing line of FIG. 20;

FIG. 29 is a top view of another embodiment of a laminated hardboard manufacturing line;

FIG. 30 is a side view of the calendaring stage of the hardboard manufacturing line of FIG. 29;

FIG. 31 is a diagrammatic and side view of a portion of a materials recycling system;

FIG. 32 is a side view of a materials recycling system and laminated hardboard manufacturing line;

FIG. 33 is a top view of the materials recycling system and laminated hardboard manufacturing line of FIGS. 31 and 32;

FIG. 34 is a mechanical properties chart comparing the tensile and flexural strength of an illustrative laminated hardboard panel with industry standards;

FIG. 35 is a mechanical properties chart comparing the flexural modulus of an illustrative laminated hardboard panel with industry standards;

Figs. a through c 36 are sectional views of the fibrous material layer subjected to various amounts of heat and pressure;

FIG. 37 is a chart showing an illustrative manufacturing process for a structural mat comprising nucleated and coupled polypropylene;

FIG. 38 is a surface view of a prior art panel which has been painted to show defects in the surface;

FIG. 39 is a surface view of a panel comprising a nucleated binder and fibers, wherein the surface that has been painted via the same method as the prior art surface shown in FIG. 38; and

FIG. 40 is a diagrammatic inside view of an illustrative manufacturing process for manufacturing a composite panel.

Claims

1. A panel comprising: a core layer having a first surface; anda second layer having a first surface adjacent the first surface of the core layer and a second surface that is an exterior surface of the panel;wherein the second layer comprises a blend of nucleated binder fibers and synthetic fibers; andwherein the exterior surface of the second layer further comprises a finishable, substantially defect and porosity free surface.

2. The panel of claim 1, wherein the nucleated binder fibers contains a nucleating agent being an aluminosilicate glass.

3. The panel of claim 2, wherein the nucleated binder fibers comprise a nucleating agent and polypropylene fibers forming nucleated polypropylene fibers.

4. The panel of claim 3, wherein the synthetic fibers are polyester fibers

5. The panel of claim 4, wherein the nucleated polypropylene fibers and polyester fibers have a blend ratio of about 85% and about 15%, respectively.

6. The panel of claim 1, wherein the nucleated binder fibers of the second layer comprises about 98% polypropylene fibers and about 2% nucleating agent.

7. The outer surface layer of claim 3, wherein the nucleating agent is an aluminosilicate glass.

8. A method of producing a panel having a finishable, substantially defect-free exposed surface, the method comprising the steps of: providing at least a core layer and a surface layer wherein the surface layer comprises nucleated binder fibers combined with synthetic fibers;ordering the layers so the surface layer will comprise an exposed surface when producing the panel;forming a composite from the core and surface layers by laying them on top of each other;removing substantially all moisture from the composite prior to compressing it;heating and compressing the composite which melts the nucleated polypropylene and reduces the thickness of the composite; andchilling and compressing the composite to reduce the thickness of the composite to a desired thickness.

9. The method of claim 8, further comprising the steps of: providing a steel belt that provides a surface that remains in contact with the outer surface of the surface layer during both the heating and compressing, and the chilling and compressing steps.

10. The method of claim 8, further comprising the steps of: cutting the composite to a desired length prior to removing the moisture from the composite.

11. The method of claim 8, further comprising the steps of: preheating the composite prior to the heating and compressing step.

12. The method of claim 8, further comprising the steps of: heating and compressing the composite simultaneously.

13. The method of claim 12, further comprising the steps of: chilling and compressing the composite simultaneously.

14. The method of claim 9, further comprising the steps of: heating the nucleated binder fibers of the surface layer to a full melt.

15. The panel of claim 5, wherein the nucleated polypropylene fibers and polyester fibers have a blend ratio of about 70-95% and about 5-30%, respectively.

16. The panel of claim 6, wherein the nucleated binder may further comprise about 2-6% nucleating agent combined with 94-98% polypropylene.

17. The panel of claim 1, wherein the nucleated binder fibers of the second layer comprises about 96% polypropylene fibers and about 4% nucleating agent.