Reinforced structural composite panel

Abstract

The utility model discloses a kind of reinforced structure composite board of glue type, comprising: a core layer, core layer has at least one surface;A surface layer, surface layer is connected by adhesive and the at least one surface of core layer is attached;Wherein, at least one surface of core layer is equipped with the groove of array distribution, groove is V-shaped groove or U-shaped groove, groove is configured to limit the glue area of adhesive, so that adhesive is concentrated distribution in groove inside, when surface layer and core layer are attached under hot-pressing condition, adhesive in groove is completely filled groove space under the action of pressure and forms glue nail structure, adhesive forms limited overflow at groove edge.The utility model reduces the adhesive usage of unit area by more than 30% under the premise of guaranteeing or even improving bonding strength by optimizing the structural design of glue area, effectively reduces production cost and formaldehyde release risk.

Description

Technical Field

[0001] This utility model belongs to the field of artificial board technology, specifically relating to a composite board structure that can significantly reduce the amount of adhesive used while ensuring structural strength, and particularly to an adhesive-saving reinforced composite board with a special groove structure. Background Technology

[0002] Engineered wood panels are widely used in various fields as an important material for modern building decoration and furniture manufacturing. Traditional composite panels mainly use adhesives to bond different layers of materials together to form a composite structure with specific properties.

[0003] Currently, common composite board manufacturing technologies mainly include full-coverage adhesive application and partial adhesive application. Full-coverage adhesive application involves evenly applying the adhesive to the entire bonding surface and then hot-pressing it. Partial adhesive application, on the other hand, applies adhesive to specific areas, reducing the amount used by optimizing adhesive distribution.

[0004] The most relevant prior art to this application is the traditional full-coverage adhesive composite board manufacturing process. The technical principle of this process is: the adhesive is evenly applied to the entire contact surface of the core layer and the surface layer by means of roller coating, spraying or brushing, so that the adhesive forms a continuous adhesive layer between the two materials. Then, hot pressing is performed under certain temperature and pressure conditions to cure the adhesive and form a strong bond.

[0005] However, existing technologies have the following technical problems: First, traditional full-coverage adhesive application methods require a large amount of adhesive, which not only increases production costs but also leads to an increase in the release of harmful substances such as formaldehyde, affecting the environmental performance of the product; second, the utilization efficiency of adhesives in planar contact is low, with most adhesives only playing a filling role and failing to fully exert their structural reinforcement effect. Utility Model Content

[0006] In view of this, this application provides an adhesive-saving reinforced structural composite panel, which solves the problems of large adhesive consumption and low utilization efficiency in the prior art.

[0007] This application provides an adhesive-saving reinforced structural composite panel, comprising:

[0008] A core layer having at least one surface;

[0009] A surface layer, said surface layer being bonded to at least one surface of the core layer by an adhesive;

[0010] The core layer has an array of grooves on at least one surface. The grooves are V-shaped or U-shaped and are configured to define the application area of ​​the adhesive, so that the adhesive is concentrated inside the groove. When the surface layer and the core layer are bonded together under hot and pressure conditions, the adhesive in the groove completely fills the groove space under pressure and forms an adhesive nail structure. The adhesive overflows to a limited extent at the edge of the groove.

[0011] The groove is a V-shaped groove with two opposing sidewalls that converge downwards to form a V-shaped cross-section. The inclination angle of the sidewalls of the V-shaped groove is 30°-60°.

[0012] The groove is a U-shaped groove with a bottom and two sidewalls. The bottom is a flat structure, and the two sidewalls and the bottom form a U-shaped cross-section. The U-shaped groove has a larger adhesive accommodating space.

[0013] The grooves are spaced 30-50mm apart, 1-3mm deep, and 2-5mm wide. The adhesive overflow band at the edge of the groove is 0.5-1.0mm wide.

[0014] The V-shaped groove has a sidewall inclination angle of 45°. The V-shaped groove is formed by CNC engraving, die forming or special roller indentation. The depth of the V-shaped groove is 2mm and the width is 3mm.

[0015] The core layer is made of particleboard, medium-density fiberboard or oriented strand board, the thickness of the core layer is 8-25mm, and the surface flatness error of the core layer does not exceed ±0.2mm.

[0016] The surface layer is made of thin wood veneer, MDF, hardboard, or decorative paper. The thickness of the surface layer is 0.2-3mm. The coverage of the surface layer and the core layer is not less than 95%. The surface layer has good flexibility to adapt to the hot pressing process.

[0017] The adhesive nail structure completely fills the groove space and forms an overflow band at the edge of the groove. The overflow band and the adhesive nail structure together constitute a three-dimensional reinforced connection structure. The adhesive nail structure forms a mechanical interlocking effect with the surface layer. The amount of adhesive used per unit area is reduced by more than 30% compared with the traditional full-coverage adhesive application. The bending strength of the composite board is increased by 5%-15% compared with the traditional planar bonding structure.

[0018] This application has the following technical effects:

[0019] By setting arrayed V-shaped or U-shaped grooves on the surface of the core layer, the adhesive is concentrated inside the grooves to form a "glue nail" structure, which significantly improves the utilization efficiency of the adhesive. While ensuring or even improving the bonding strength, the amount of adhesive used per unit area is reduced by more than 30%, effectively reducing production costs.

[0020] The adhesive nail structure formed in the groove creates a mechanical interlocking effect with the surface layer, reducing interface slippage and increasing the bending strength of the composite board by 5%-15% compared to traditional planar adhesive structures. At the same time, it exhibits better moisture resistance in damp heat cycling tests.

[0021] The reduction in adhesive usage directly lowers the formaldehyde emission of the finished boards. Tests show that the formaldehyde emission is 25%-35% lower than that of similar traditional products, making it easier to meet the requirements of E0 grade or even higher environmental protection levels, and complying with increasingly stringent environmental regulations. Attached Figure Description

[0022] To more clearly illustrate the technical solutions of the embodiments of this disclosure, the accompanying drawings used in the embodiments will be briefly described below. These drawings are incorporated in and constitute a part of this specification. They illustrate embodiments conforming to this disclosure and, together with the specification, serve to explain the technical solutions of this disclosure. It should be understood that the following drawings only show some embodiments of this disclosure and should not be considered as limiting the scope. Those skilled in the art can obtain other related drawings based on these drawings without creative effort.

[0023] Figure 1 This is a schematic diagram of the adhesive-saving reinforced composite panel of Embodiment 1 of this utility model;

[0024] Figure 2 This is an exploded perspective view of the glue-saving reinforced composite panel of Embodiment 2 of this utility model;

[0025] Figure 3 This is a partial cross-sectional detail view of Embodiment 2 of this utility model.

[0026] Wherein: 1-core layer; 2-surface layer; 3-groove; 4-glue nail; 5-overflow strip. Detailed Implementation

[0027] To make the objectives, technical solutions, and advantages of the embodiments of this disclosure clearer, the technical solutions of the embodiments of this disclosure will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this disclosure, and not all of them. The components of the embodiments of this disclosure described and shown in the accompanying drawings can generally be arranged and designed in various different configurations. Therefore, the following detailed description of the embodiments of this disclosure provided in the accompanying drawings is not intended to limit the scope of the claimed disclosure, but merely represents selected embodiments of this disclosure. All other embodiments obtained by those skilled in the art based on the embodiments of this disclosure without inventive effort are within the scope of protection of this disclosure.

[0028] It should be noted that similar labels and letters in the following figures indicate similar items. Therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures.

[0029] In this document, the term "and / or" merely describes a relationship, indicating that three relationships can exist. For example, A and / or B can represent three cases: A alone, A and B simultaneously, and B alone. Furthermore, the term "at least one" in this document means any combination of at least two of any one or more elements. For example, including at least one of A, B, and C can mean including any one or more elements selected from the set consisting of A, B, and C.

[0030] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present utility model.

[0031] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0032] like Figure 1 As shown, the adhesive-saving reinforced structural composite panel provided by this utility model includes a core layer 1, a surface layer 2, and an array of grooves 3 disposed on the surface of the core layer 1. Through a special structural design, it achieves efficient utilization of adhesive and improved structural strength.

[0033] like Figure 2 and Figure 3 As shown, this application provides an adhesive-saving reinforced structural composite panel, comprising:

[0034] A core layer having at least one surface;

[0035] A surface layer, said surface layer being bonded to at least one surface of the core layer by an adhesive;

[0036] The core layer has an array of grooves 3 on at least one surface. The grooves 3 are V-shaped or U-shaped and are configured to define the application area of ​​the adhesive, so that the adhesive is concentrated inside the grooves 3. When the surface layer and the core layer are bonded together under hot and pressure conditions, the adhesive in the grooves 3 completely fills the space of the grooves 3 under pressure and forms a glue nail structure. The adhesive overflows to a limited extent at the edge of the grooves 3.

[0037] The groove 3 is a V-shaped groove with two opposing sidewalls that converge downwards to form a V-shaped cross-section. The inclination angle of the sidewalls of the V-shaped groove is 30°-60°.

[0038] The groove 3 is a U-shaped groove with a bottom and two side walls. The bottom is a flat structure, and the two side walls and the bottom form a U-shaped cross-section. The U-shaped groove has a larger adhesive accommodating space.

[0039] The grooves 3 are spaced 30-50mm apart, 1-3mm deep, and 2-5mm wide. The adhesive overflow band 5 at the edge of the groove 3 is 0.5-1.0mm wide. This overflow band is the adhesive transition band formed by the adhesive overflow at the edge of the groove 3.

[0040] The V-shaped groove has a sidewall inclination angle of 45°. The V-shaped groove is formed by CNC engraving, die forming or special roller indentation. The depth of the V-shaped groove is 2mm and the width is 3mm.

[0041] The core layer is made of particleboard, medium-density fiberboard or oriented strand board, the thickness of the core layer is 8-25mm, and the surface flatness error of the core layer does not exceed ±0.2mm.

[0042] The surface layer is made of thin wood veneer, MDF, hardboard, or decorative paper. The thickness of the surface layer is 0.2-3mm. The coverage of the surface layer and the core layer is not less than 95%. The surface layer has good flexibility to adapt to the hot pressing process.

[0043] The adhesive nail structure completely fills the space of the groove 3 and forms an overflow band 5 at the edge of the groove 3. The overflow band 5 and the adhesive nail structure together constitute a three-dimensional reinforced connection structure. The adhesive nail structure forms a mechanical interlocking effect with the surface layer. The amount of adhesive used per unit area is reduced by more than 30% compared with the traditional full-coverage adhesive application. The bending strength of the composite board is increased by 5%-15% compared with the traditional planar bonding structure.

[0044] The core layer 1 serves as the basic load-bearing structure of the composite board, and its material can be conventional engineered wood products such as particleboard, medium-density fiberboard, or oriented strand board. The thickness of the core layer 1 is typically 8-25mm, and can be adjusted according to the strength requirements of different applications. Specifically, for general decorative purposes, a core layer 1 thickness of 8-15mm can be selected; for structural load-bearing applications, a core layer 1 thickness of 18-25mm can be selected. The surface flatness error of the core layer 1 is controlled within ±0.2mm to ensure the processing accuracy of the groove 3 and the subsequent bonding quality with the surface layer 2.

[0045] At least one surface of the core layer 1 has an array of grooves 3 arranged in a regular pattern, such as a straight line, an alternating pattern, or a grid pattern. The spacing between the grooves 3 is 30-50 mm. This spacing range is optimized to ensure sufficient bonding density while maximizing adhesive savings. For example, in standard applications, the spacing between the grooves 3 is preferably 40 mm, which allows approximately 625 grooves 3 to be formed on a 1 square meter core layer surface, creating a uniformly distributed adhesive network.

[0046] like Figure 1 As shown in Embodiment 1, when the groove 3 is a U-shaped groove, it has a flat bottom structure and two opposing sidewalls, which together form a U-shaped cross-section. Compared to a V-shaped groove, the U-shaped groove has a larger adhesive capacity, making it suitable for applications requiring higher bonding strength. The depth of the U-shaped groove is also 1-3 mm, but due to its planar bottom structure, its effective volume is approximately 15-20% larger than that of a V-shaped groove of the same size. It should be noted that, for ease of understanding, Figure 1 The groove 3 is an exploded view pattern, intended to show the shape of the groove. In the actual composite board, groove 3 is a groove structure rather than a protrusion structure.

[0047] The cross-sectional shape of the groove 3 can be V-shaped or U-shaped, each with its own technical characteristics and applicable scenarios. For example... Figure 2As shown in Embodiment 2, when the groove 3 is a V-shaped groove, it has two opposing sidewalls that converge downwards to form a V-shaped cross-section. The inclination angle of the sidewalls of the V-shaped groove is designed to be 30°-60°, preferably 45°. This angle design allows the adhesive to fully fill the groove space during hot pressing, while forming a good mechanical locking effect. The depth of the V-shaped groove is 1-3mm, preferably 2mm; the width is 2-5mm, preferably 3mm.

[0048] The groove 3 can be processed in several ways. First, CNC engraving is the most precise method, capable of achieving complex groove shapes and strict dimensional control, making it particularly suitable for small-batch or special-specification products. Second, die forming is suitable for mass production, using a special mold to press the groove 3 onto the surface of the core layer 1, resulting in high production efficiency and low cost. Third, dedicated roller indentation is a continuous processing method, using rollers with groove patterns to roll and form a regular array of grooves on the surface of the core layer 1, suitable for continuous processing of large-format panels.

[0049] Surface layer 2 serves as the outer surface decoration and protective layer of the composite board. Its material can be selected from materials such as thin wood veneer, MDF, hardboard, or decorative paper. The thickness of surface layer 2 is 0.2-3mm, depending on the specific application requirements. When using thin wood veneer, the thickness is typically 0.2-0.6mm, providing the texture and feel of natural wood; when using MDF or hardboard, the thickness can be selected from 0.8-3mm, providing better surface smoothness and strength; when using decorative paper, the thickness is typically 0.1-0.3mm, mainly used for printing decorative patterns.

[0050] The surface layer 2 must have good flexibility to adapt to the hot pressing process, especially in the groove 3 area, where the surface layer 2 needs to conform to the shape of the groove 3 without cracking or delamination. The bonding area between the surface layer 2 and the core layer 1 should cover no less than 95% to ensure the integrity and aesthetics of the overall structure.

[0051] Formation mechanism of glued nail structure

[0052] The adhesive nail 4 is the core technical feature of this utility model, and its formation process is as follows: During adhesive application, a precise quantitative coating technology is used, requiring only precise injection of the adhesive into the groove 3. Spraying, roller coating, or precision dispensing methods can be used to ensure that the adhesive is mainly distributed inside the groove 3, avoiding excessive coating on the planar area.

[0053] In the hot-pressing process, the temperature is typically controlled between 120-180℃, the pressure between 1.5-3.0MPa, and the time between 3-10 minutes. Specific parameters need to be adjusted according to the type of adhesive and the thickness of the board. When the surface layer 2 and the core layer 1 are bonded under hot-pressing conditions, the adhesive in the groove 3 undergoes the following changes under high temperature and high pressure: First, the adhesive softens and flows fully under heat, completely filling the space of the groove 3; second, under pressure, the adhesive slightly overflows towards the edge of the groove 3, forming an overflow band 5 with a width of 0.5-1.0mm; finally, the adhesive rapidly cures under high temperature conditions, forming a strong adhesive nail 4 structure within the groove 3.

[0054] The fit between the adhesive nail 4 and the groove 3 forms a mechanical connection structure similar to a mortise and tenon joint. This connection method relies not only on the chemical bonding force of the adhesive but also on the mechanical interlocking effect created by the geometric shape. The overflow strip 5 at the edge, together with the adhesive nail 4, constitutes a three-dimensional reinforced connection structure, effectively preventing slippage and separation between the surface layer 2 and the core layer 1.

[0055] This invention achieves significant technical benefits through the aforementioned structural design. Regarding adhesive usage, since the adhesive is primarily concentrated inside the groove 3, the amount of adhesive used per unit area can be reduced by 30%-40% compared to traditional full-coverage application. For example, for 1 square meter of board, the traditional method requires approximately 150-200g of adhesive, while this invention only requires 100-120g.

[0056] In terms of strength performance, the mechanical interlocking effect of the adhesive nail 4 structure increases the bending strength of the composite board by 5%-15%. Tests show that the static bending strength of the composite board using this structure can reach 25-35 MPa, while the traditional structure is typically 20-28 MPa. Furthermore, in a 24-hour water immersion test, the water absorption thickness expansion rate of this structure is 20%-30% lower than that of the traditional structure, demonstrating better dimensional stability.

[0057] In terms of environmental performance, the reduction in adhesive usage directly lowers formaldehyde emissions. Tests show that the formaldehyde emission of composite boards using this new structure is 0.08-0.12 mg / L, while that of traditional structures is typically 0.15-0.20 mg / L, representing a reduction of 25%-35%, making it easier to meet E0 environmental protection requirements.

[0058] It should be noted that this utility model can also have various variations. The arrangement of the grooves 3 can be adjusted according to specific needs. For example, a honeycomb arrangement can further optimize the adhesive distribution. The shape of the grooves 3 can also be elliptical, trapezoidal, or other geometric shapes, as long as they can form an effective adhesive nail 4 structure. The material combination of the core layer 1 and the surface layer 2 can be flexibly selected according to the intended use of the final product.

[0059] Furthermore, this invention can also be applied to double-sided laminated panels, where grooves 3 are provided on both surfaces of the core layer 1 and the surface layer 2 is adhered to them respectively, forming a symmetrical composite structure. This structure maintains the glue-saving effect while further improving the overall performance and aesthetics of the panel.

[0060] In summary, this utility model, through its ingenious structural design, significantly reduces adhesive usage and production costs while ensuring or even improving product performance, and also improves environmental performance. It has high practical value and promising prospects for promotion.

Claims

1. A glue-saving reinforced structural composite panel, characterized in that, include: At least one core layer, the core layer having at least one surface; At least one surface layer, said surface layer being bonded to at least one surface of the core layer by an adhesive; The core layer has an array of grooves on at least one surface. The grooves are V-shaped or U-shaped and are configured to define the application area of ​​the adhesive, so that the adhesive is concentrated inside the groove. When the surface layer and the core layer are bonded together under hot and pressure conditions, the adhesive in the groove completely fills the groove space under pressure and forms an adhesive nail structure. The adhesive overflows to a limited extent at the edge of the groove.

2. The adhesive-reinforced composite panel according to claim 1, characterized in that, The groove is a V-shaped groove with two opposing sidewalls that converge downwards to form a V-shaped cross-section. The inclination angle of the sidewalls of the V-shaped groove is 30°-60°.

3. The glue-saving reinforced structural composite panel according to claim 1, characterized in that, The groove is a U-shaped groove with a bottom and two sidewalls. The bottom is a flat structure, and the two sidewalls and the bottom form a U-shaped cross-section. The U-shaped groove has a larger adhesive accommodating space.

4. The adhesive-reinforced composite panel according to claim 1, characterized in that, The grooves are spaced 30-50mm apart, 1-3mm deep, and 2-5mm wide. The adhesive overflow band at the edge of the groove is 0.5-1.0mm wide.

5. The glue-saving reinforced structural composite panel according to claim 2, characterized in that, The V-shaped groove has a sidewall inclination angle of 45°. The V-shaped groove is formed by CNC engraving, die forming or special roller indentation. The depth of the V-shaped groove is 2mm and the width is 3mm.

6. The glue-saving reinforced structural composite panel according to claim 1, characterized in that, The core layer is made of particleboard, medium-density fiberboard or oriented strand board, the thickness of the core layer is 8-25mm, and the surface flatness error of the core layer does not exceed ±0.2mm.

7. The adhesive-reinforced composite panel according to claim 1, characterized in that, The surface layer is made of thin wood veneer, MDF, hardboard, or decorative paper. The thickness of the surface layer is 0.2-3mm. The coverage of the surface layer and the core layer is not less than 95%. The surface layer has good flexibility to adapt to the hot pressing process.

8. The glue-saving reinforced structural composite panel according to claim 1, characterized in that, The adhesive nail structure completely fills the groove space and forms an overflow band at the edge of the groove. The overflow band and the adhesive nail structure together constitute a three-dimensional reinforced connection structure, and the adhesive nail structure forms a mechanical interlock with the surface layer.

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