Composite board

Abstract

A composite board comprises a composite core board and two metal boards. The composite core plate comprises a supporting layer unit and two interlayer units which are respectively adhered to the upper side and the lower side of the supporting layer unit. The supporting layer unit and the interlayer unit are matched to define at least one first space and at least one second space which are spaced from each other. The supporting layer unit is provided with a core layer and two first connecting layers which are respectively adhered to the upper side and the lower side of the core layer. And each interlayer unit is provided with a middle layer and a second connecting layer which is adhered to the middle layer and the first connecting layer on the corresponding side of the supporting layer unit. And the composite core plate is made of polyolefin. And the metal plates are respectively adhered to the interlayer units of the composite core plate. Through the design, the weight of the composite core plate can be reduced.

Description

Technical Field

[0001] The utility model relates to a plate, in particular to a composite plate. Background Art

[0002] To achieve sustainable global environmental development, people are actively working to save energy and reduce carbon emissions in various ways. One such effort is replacing existing fuel-powered vehicles with electric vehicles. However, the heavy weight of batteries in electric trucks and trailers used to transport goods inevitably reduces cargo capacity and transportation efficiency. Given the difficulty of reducing battery weight, manufacturers are working to reduce the weight of the vehicles themselves.

[0003] A known composite panel, suitable for use in vehicle bodies such as, but not limited to, trucks and trailers, comprises a core layer having two opposing mating surfaces and two metal layers bonded to the mating surfaces of the core layer. Because the core layer is typically made of solid or foamed material, combined with the weight of the metal layers, the known composite panel is extremely heavy, and improvements are needed. Utility Model Content

[0004] The purpose of the present invention is to provide a composite board that can improve at least one disadvantage of the prior art.

[0005] The composite plate of the utility model comprises a composite core plate and two metal plates.

[0006] The composite core panel includes a support layer unit and two sandwich units bonded to the upper and lower sides of the support layer unit, respectively. The support layer unit and the sandwich unit cooperate to define at least one first space and at least one second space spaced apart from each other. The support layer unit has a core layer and two first connecting layers bonded to the upper and lower sides of the core layer, respectively. Each of the sandwich units has an intermediate layer and a second connecting layer bonded to the intermediate layer and the first connecting layer on the corresponding side of the support layer unit. The composite core panel is made of polyolefin. The metal plates are bonded to the sandwich units of the composite core panel, respectively.

[0007] In the composite board of the present invention, the melting point of each of the first connecting layers is lower than the melting point of the core layer, and the melting point of each of the second connecting layers is lower than the melting point of the intermediate layer.

[0008] In the composite board of the present invention, the melting point of each of the first connecting layers is the same as the melting point of each of the second connecting layers, and the materials of each of the first connecting layers and each of the second connecting layers are the same.

[0009] The composite board material of the present invention, the support layer unit includes a base wall with opposite top and bottom surfaces, a plurality of first support structures extending downward from the top surface and bonded to the sandwich unit below, and a plurality of second support structures protruding upward from the bottom surface and bonded to the sandwich unit above. The first support structure and the second support structure are arranged in an alternating manner, the first support structure cooperates with the sandwich unit above to define the at least one first space, and the second support structure cooperates with the sandwich unit below to define the at least one second space.

[0010] In the composite board of the present invention, the support layer unit cooperates with the sandwich unit to define several first spaces and at least one second space spaced apart from each other, the support layer unit includes several third support structures spaced apart from each other, each of the third support structures is a barrel-shaped structure with an opening toward one of the sandwich units, and has a third end wall connected to the other sandwich unit, and a third annular wall extending downward from the periphery of the third end wall and connected to one of the sandwich units, each of the third support structures cooperates with one of the sandwich units to define the closed first space, the support layer unit also includes a connecting wall spanning the outer periphery of the open end of the third support structure, the connecting wall is connected to one of the sandwich units, and the connecting wall, the third support structure and the other sandwich unit cooperate to define the at least one second space.

[0011] In the composite board material of the present invention, the support layer unit cooperates with the sandwich unit to define several first spaces and several second spaces spaced apart from each other. The support layer unit includes several fourth support structures arranged in sequence along the first direction and connected to form an upper and lower continuous bending shape. Each of the fourth support structures cooperates with one of the sandwich units to define one of the first spaces. Each of the fourth support structures extends along a second direction orthogonal to the first direction, and every two adjacent fourth support structures cooperate with another sandwich unit to define one of the second spaces. The first space and the second space are arranged at intervals along the first direction.

[0012] The beneficial effect of the present invention is that the design of defining at least one first space and at least one second space spaced apart by the cooperation between the support layer unit and the sandwich unit of the composite core panel helps to reduce the weight of the composite core panel. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] Other features and effects of the present invention will be clearly presented in the embodiments with reference to the accompanying drawings, in which:

[0014] Figure 1This is an incomplete exploded perspective view illustrating a first embodiment of the composite board of the present invention;

[0015] Figure 2 is a fragmentary side cross-sectional view illustrating the first embodiment;

[0016] Figure 3 is a schematic diagram illustrating the manufacturing process of the first embodiment;

[0017] Figure 4 This is an incomplete three-dimensional diagram illustrating a second embodiment of the composite board of the present invention;

[0018] Figure 5 It is an incomplete three-dimensional diagram illustrating a third embodiment of the composite board of the present invention. DETAILED DESCRIPTION

[0019] Before the present invention is described in detail, it should be noted that similar components are represented by the same reference numerals in the following description.

[0020] See Figure 1 、 2 A first embodiment of the composite board of the present invention comprises a composite core board 3 and two metal plates 4 bonded to the upper and lower sides of the composite core board 3 respectively.

[0021] The composite core panel 3 includes a support layer unit 5 and two sandwich units 6 bonded to the upper and lower sides of the support layer unit 5 respectively.

[0022] The support layer unit 5 includes a base wall 51 having a top surface 511 and a bottom surface 512, which are opposite to each other. A plurality of first support structures 52 are recessed downwardly from the top surface 511, and a plurality of second support structures 53 are protruded upwardly from the bottom surface 512. The first support structures 52 and the second support structures 53 are arranged alternately in a matrix.

[0023] The base wall 51 is spaced between the sandwich units 6. Each first support structure 52 comprises a first end wall 521 bonded to the sandwich unit 6 below, and an annular first ring wall 522 connected between the periphery of the first end wall 521 and the base wall 51. The diameter of the first ring wall 522 gradually decreases from top to bottom.

[0024] Each of the second support structures 53 comprises a second end wall 531 bonded to the sandwich unit 6 above, and a second annular wall 532 connected between the periphery of the second end wall 531 and the base wall 51. The diameter of the second annular wall 532 is gradually reduced from bottom to top.

[0025] The first support structure 52 of the support layer unit 5 cooperates with the upper interlayer unit 6 to define a first space 70. The second support structure 53 of the support layer unit 5 cooperates with the lower interlayer unit 6 to define a second space 71. The second space 71 is separated from the first space 70.

[0026] It should be noted that, in the first embodiment, the cross-section of each of the first supporting structures 52 and each of the second supporting structures 53 is approximately circular, but in practice, it may be, for example but not limited to, an elliptical, quadrilateral, or hexagonal shape.

[0027] The support layer unit 5 is made of polyolefin and comprises a core layer 54 and two first connecting layers 55 respectively bonded to the upper and lower sides of the core layer 54. The melting point of each first connecting layer 55 is lower than that of the core layer 54.

[0028] Each sandwich unit 6 is made of polyolefin and includes a middle layer 61, a second connecting layer 62 bonded to the middle layer 61 and the first connecting layer 55 on the corresponding side of the support layer unit 5, and a third connecting layer 63 bonded to the middle layer 61 and the corresponding side of the metal plate 4. The melting point of the second connecting layer 62 is lower than that of the middle layer 61 and is the same as that of the first connecting layer 55. The melting point of the third connecting layer 63 is lower than that of the middle layer 61 and is the same as that of the second connecting layer 62.

[0029] The core layer 54 of the support layer unit 5 and the intermediate layer 61 of each sandwich unit 6 are each polymerized from a first material, wherein the first material includes a first monomer. Each first connecting layer 55 of the support layer unit 5 and each second connecting layer 62 and third connecting layer 63 of the sandwich unit 6 are each polymerized from a second material, wherein the second material includes the first monomer and a second monomer.

[0030] In this first embodiment, the first monomer is propylene. Specifically, the core layer 54 and each of the intermediate layers 61 are each made of polypropylene with a melting point of 165°C (as measured by Differential Scanning Calorimetry (DSC)). Each of the first tie layers 55, each of the second tie layers 62, and each of the third tie layers 63 are each made of a polypropylene copolymer with a melting point of 130-147°C.

[0031] Because the melting points of each of the first connecting layers 55 and each of the second connecting layers 62 are lower than those of the core layer 54 and each of the intermediate layers 61, after each of the first connecting layers 55 and each of the second connecting layers 62 has been heat-fused but before they have bonded, the heat-fused state of each of the first connecting layers 55 and each of the second connecting layers 62 is less likely to be affected by a drop in temperature, thereby affecting the adhesion between each of the first connecting layers 55 and each of the second connecting layers 62. In other words, the composite board of the present invention has better adhesion between the intermediate layer 61 and the core layer 54.

[0032] Furthermore, during the process of heating and hot-melting each of the first connection layers 55 and each of the second connection layers 62 , the material state of the core layer 54 and each of the intermediate layers 61 is not affected.

[0033] It should be noted that in other embodiments of the present invention, the first material further includes a third monomer, and the third monomer is ethylene. Specifically, the core layer 54 and each of the intermediate layers 61 are each a propylene-ethylene block copolymer with a melting point of 165°C, and each of the first tie layer 55, each of the second tie layer 62, and each of the third tie layer 63 are each a polypropylene copolymer with a melting point of 130-147°C.

[0034] In this first embodiment, the first material includes the first monomer, the second material includes the first monomer and the second monomer, and the first monomer is propylene. However, this is not a limitation in practice; the second material may include only the first monomer, the first monomer being ethylene, and the density of the first material being greater than the density of the second material. Specifically, the core layer 54 and each of the intermediate layers 61 are each made of high-density polyethylene (HDPE), which has a melting point of 135°C, and each of the first tie layers 55, each of the second tie layers 62, and each of the third tie layers 63 are each made of low-density polyethylene (LDPE), which has a lower density than the HDPE and a melting point of 105°C.

[0035] In addition, in other embodiments of the present invention, the first material includes the first monomer. The second material includes the first monomer and the second monomer. The first monomer is ethylene, and the second monomer is vinyl acetate. Specifically, the core layer 54 and each of the intermediate layers 61 are respectively high-density polyethylene (HDPE) with a melting point of 135°C, and each of the first connecting layers 55, each of the second connecting layers 62, and each of the third connecting layers 63 are respectively ethylene-vinyl acetate copolymers polymerized from ethylene and vinyl acetate, with a melting point of 76-93°C.

[0036] In addition, the core layer 54 and each of the intermediate layers 61 may further be added with, for example but not limited to, one of talc, calcium carbonate, mica, glass fiber, carbon fiber and silica according to purposes such as fire protection and strength improvement.

[0037] The metal plates 4 are respectively bonded to the sandwich units 6 of the composite core panel 3. Each of the metal plates 4 includes a metal layer 41 and a glue layer 42 bonded to the metal layer 41 and the third connection layer 63 of the sandwich unit 6 on the corresponding side.

[0038] Each of the metal layers 41 can be a metal layer with good rigidity and strength, such as an aluminum alloy layer, a steel layer, a galvanized steel layer, an aluminum-zinc-plated steel layer, a zinc alloy layer, a copper alloy layer, a stainless steel layer or a titanium alloy layer.

[0039] In the first embodiment, each adhesive layer 42 is an adhesive film, and the material of each adhesive layer 42 only needs to be able to achieve the purpose of bonding the corresponding metal layer 41 and the corresponding hot-melt third connection layer 63 of the interlayer unit 6 .

[0040] See Figure 3 When manufacturing the composite board of the present invention, the first connecting layer 55 of the support layer unit 5 and the core layer 54 are co-extruded from the extruder to form a hot melt state and can be combined. The second connecting layer 62, the third connecting layer 63 and the intermediate layer 61 of each sandwich unit 6 are co-extruded from the extruder to form a hot melt state and can be combined. Then, the first connecting layer 55 is heated (such as Figure 3 As shown by the arrow in the middle, the supporting layer unit 5 is in a hot-melt state. When the supporting layer unit 5 is transferred to two correspondingly arranged first pressing rollers 81, although it is no longer heated so that the temperature naturally drops, the first connecting layer 55 and the second connecting layer 62 still remain in a hot-melt state because of their lower melting points. The sandwich unit 6 and the supporting layer unit 5 can be pressed by the first pressing rollers 81 and bonded to form the composite core panel 3.

[0041] Next, the two adhesive films are respectively transferred to the two sides of the composite core panel 3 to be adhered to the two sides of the composite core panel 3 to form the adhesive layer 42, and then the composite core panel 3 and the adhesive layer 42 are transferred to two correspondingly arranged second pressing rollers 82, and then the composite core panel 3, the adhesive layer 42, and the metal layer 41 are heated and pressed by the heated second pressing rollers 82 to bond them together to form the composite panel of this utility model.

[0042] See Figure 4 The structure of a second embodiment of the composite board of the present invention is substantially the same as that of the first embodiment, except for the structural design of the support layer unit 5 of the composite core panel 3. For ease of description, only the differences between the embodiments will be described below.

[0043] In this second embodiment, the support layer unit 5 cooperates with the interlayer unit 6 to define a plurality of spaced first spaces 70 and a second space 71. The support layer unit 5 includes a plurality of spaced third support structures 56 in a downwardly opening barrel-shaped configuration, and a connecting wall 57 spanning the outer peripheries of the open ends of the third support structures 56 and bonded to the interlayer unit 6 located below.

[0044] Each third support structure 56 comprises a third end wall 561 bonded to the upper sandwich unit 6, and a third annular wall 562 extending downward from the periphery of the third end wall 561 and bonded to the lower sandwich unit 6. The diameter of the third annular wall 562 gradually increases from top to bottom, and the third annular wall 562, the third end wall 561, and the lower sandwich unit 6 cooperate to define the enclosed first space 70. The connecting wall 57, the third support structure 56, and the upper sandwich unit 6 cooperate to define the second space 71, which is spaced apart and surrounds the first space 70.

[0045] In the second embodiment, the diameter of the third annular wall 562 gradually increases from top to bottom. However, in practice, the third annular wall 562 may also extend vertically with a constant diameter.

[0046] See Figure 5 The structure of a third embodiment of the composite board of the present invention is substantially the same as that of the first embodiment, except for the structural design of the support layer unit 5 of the composite core panel 3. For ease of description, only the differences between the embodiments will be described below.

[0047] In this third embodiment, the support layer unit 5 and the interlayer unit 6 cooperate to define a plurality of spaced first spaces 70 and a plurality of spaced second spaces 71. The support layer unit 5 includes a plurality of fourth support structures 58 arranged sequentially along a first direction D1 and connected in a vertically continuous curved configuration. Each fourth support structure 58 extends along a second direction D2 orthogonal to the first direction D1 and cooperates with the interlayer unit 6 above to define one of the first spaces 70. Each pair of adjacent fourth support structures 58 cooperates with the interlayer unit 6 below to define a second space 71 located between two adjacent first spaces 70.

[0048] In this third embodiment, the first direction D1 is defined as the left-right direction, and accordingly, the second direction D2 is defined as the front-back direction. Specifically, each fourth support structure 58 comprises a first support wall 581 bonded to the upper interlayer unit 6 and extending downward and rightward, and a second support wall 582 extending upward and rightward from the first support wall 581. The second support wall 582 is bonded to the lower interlayer unit 6.

[0049] The first support wall 581 and the second support wall 582 of each fourth support structure 58 cooperate with the interlayer unit 6 above to define the first space 70. The second support wall 582 of each fourth support structure 58 and the first support wall 581 of the connected fourth support structure 58 cooperate with the interlayer unit 6 below to define the second space 71.

[0050] In the third embodiment, the fourth supporting structure 58 is in a vertically continuous bending shape. However, in practice, the fourth supporting structure 58 may also be in a vertically continuous square wave shape or sawtooth shape.

[0051] In summary, the design of defining at least one first space 70 and at least one second space 71 spaced apart from each other by the support layer unit 5 and the sandwich unit 6 of the composite core panel 3 helps to reduce the weight of the composite core panel 3 .

[0052] In addition, the melting point of each first connecting layer 55 of the supporting layer unit 5 is lower than the melting point of the core layer 54, the melting point of each second connecting layer 62 of the sandwich unit 6 is lower than the melting point of the intermediate layer 61, and the melting point of each first connecting layer 55 and the melting point of each second connecting layer 62 are the same temperature and made of the same material. This makes the composite board material of the present invention have the advantage of good adhesion between the intermediate layer 61 and the core layer 54, and can make each first connecting layer 55 and each second connecting layer 62 reach a hot-melt state at a lower temperature, which also has the advantage of saving energy.

[0053] The above description is merely an embodiment of the present invention and should not be used to limit the scope of implementation of the present invention. All simple equivalent changes and modifications made according to the claims and description of the present invention are still within the scope of the present invention.

Claims

1. A composite panel comprising a composite core panel and two metal plates, wherein the composite core panel comprises a support layer unit and two sandwich units bonded to upper and lower sides of the support layer unit, respectively, and the metal plates are bonded to the sandwich units of the composite core panel, characterized in that: The supporting layer unit and the sandwich unit cooperate to define at least one first space and at least one second space separated from each other. The supporting layer unit has a core layer and two first connecting layers respectively bonded to the upper and lower sides of the core layer. Each of the sandwich units has an intermediate layer and a second connecting layer bonded to the intermediate layer and the first connecting layer on the corresponding side of the supporting layer unit. The material of the composite core panel is polyolefin.

2. The composite plate according to claim 1, wherein: The melting point of each of the first connecting layers is lower than the melting point of the core layer, and the melting point of each of the second connecting layers is lower than the melting point of the intermediate layer.

3. The composite plate according to claim 2, wherein: The melting point of each of the first connection layers is the same as the melting point of each of the second connection layers, and the materials of each of the first connection layers and each of the second connection layers are the same.

4. The composite plate according to claim 1, wherein: The supporting layer unit includes a base wall having opposite top and bottom surfaces, several first supporting structures extending downward from the top surface and bonded to the interlayer unit below, and several second supporting structures protruding upward from the bottom surface and bonded to the interlayer unit above. The first supporting structure and the second supporting structure are arranged alternately, and the first supporting structure cooperates with the interlayer unit above to define the at least one first space, and the second supporting structure cooperates with the interlayer unit below to define the at least one second space.

5. The composite plate according to claim 1, wherein: The supporting layer unit cooperates with the interlayer unit to define several first spaces and at least one second space spaced apart from each other. The supporting layer unit includes several third supporting structures spaced apart from each other. Each of the third supporting structures is a barrel-shaped structure with an opening toward one of the interlayer units, and has a third end wall connected to the other interlayer unit, and a third annular wall extending downward from the periphery of the third end wall and connected to one of the interlayer units. Each of the third supporting structures cooperates with one of the interlayer units to define the closed first space. The supporting layer unit also includes a connecting wall spanning the outer periphery of the open end of the third supporting structure, and the connecting wall is connected to one of the interlayer units. The connecting wall, the third supporting structure and the other interlayer unit cooperate to define the at least one second space.

6. The composite plate according to claim 1, wherein: The support layer unit cooperates with the interlayer unit to define several first spaces and several second spaces spaced apart from each other. The support layer unit includes several fourth support structures arranged in sequence along the first direction and connected to form an upper and lower continuous bend. Each of the fourth support structures cooperates with one of the interlayer units to define one of the first spaces. Each of the fourth support structures extends along a second direction orthogonal to the first direction, and every two adjacent fourth support structures cooperate with another interlayer unit to define one of the second spaces. The first space and the second space are arranged at intervals along the first direction.

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