Panel derived from wood with a corrugated cardboard core

Abstract

The invention relates to a panel derived from wood, the central core of which is made of corrugated cardboard, the panel being in particular intended for the manufacture of fixtures or furniture, for decoration and millwork, or for construction. The panel according to the invention is characterized by a collection of materials with completely opposite uses but each originating from the wood industry and the combination of which yields an innovative material or product of varied, diverse and improved properties, characteristics and performance. This new material combines the main qualities of lightness in weight, robustness, an attractive appearance, versatility, insulation, and ease of machining and assembly, all so as to obtain a safe and environmentally friendly product. Its wide variety of combinations in multiple formats, thicknesses and finishes allows the CCC panel with a corrugated cardboard core to cover a wide range of fields of application.

Description

Wood-based panel with a corrugated cardboard core

[0001] The invention relates to a wood-derived panel whose central core is composed of corrugated cardboard, particularly intended for the manufacture of furniture for fittings or furnishings, decoration and interior joinery, construction.

[0002] Wood-based panels, such as MDF (Medium Density Fiberboard), raw or melamine-faced particleboard (also known as chipboard or melamine-faced board), OSB (Oriented Strand Board), and plywood, are widely used in interior design and furniture making, joinery, and construction. They are made of natural wood fibers, particles, lamellae, chips, or sheets bonded together to form panels with varying properties. Their main advantages are their strength and ease of working. They are available in different sizes, thicknesses, and finishes for all types of projects, including interior design, decoration, furniture making, joinery, and construction.

[0003] Wood-based panels are heavy, despite a less dense core, which limits their handling and therefore their uses. The density of these composite panels leads to premature wear of the blades of the tools used to cut them. They do not offer sufficient acoustic, sound, or thermal insulation properties to be used for insulation purposes unless reinforced with an insulating material. Particleboard and MDF also have the disadvantage of splitting easily and swelling when the different pieces of particleboard and MDF are screwed together at the screw locations without proper precautions or pre-drilling.

[0004] On the other hand, the edges of ordinary MDF panels have the disadvantage of requiring additional preparation work before varnishing, lacquering or painting said panels, otherwise the latter would be absorbed too quickly and not uniform with its faces, due to their porous properties, in order to obtain a surface condition of the faces and edges that is roughly similar once finished.

[0005] Strong, lightweight, and easy to handle, cardboard is made from cellulose fibers, themselves created from wood or recycled cardboard and paper. During its life cycle, cardboard can be recycled at least 25 times without losing any of its qualities. Recycling thus gives it a second life and conserves the planet's resources. It is economically attractive due to its low cost compared to wood or its derivatives. It is also known that cardboard, particularly corrugated cardboard thanks to the air trapped in the fluting, has high thermal resistance as well as sound and acoustic insulation.

[0006] The use of a corrugated cardboard or cardboard sheet core between two outer layers is well-known, but it's not widely recognized that these outer layers can be wood-based panels. The advantages of such a system include improved sound, acoustic, and thermal insulation, while retaining the benefits of wood-based panels, allowing them to be finished in any way, in addition to their environmental benefits. These panels typically consist of laminate, plastic, or wood veneer sheets, sometimes coated with a plastic film to make them watertight. They are primarily used in the manufacture of packaging, advertising displays, and wall coverings. They are thin and / or not designed to be joined to other panels of the same design for the production of interior furniture or fixtures.

[0007] Lightweight construction panels are known to consist of a top and bottom cover plate sandwiched between them by a lightweight intermediate layer composed of a honeycomb structure or similar material, or a layer of foam or extruded polystyrene. However, these types of panels, or similar materials, have the particularity that, after cutting, the individual pieces cannot be assembled to create furniture or other items without reinforcement in place of the lightweight intermediate layer at the joint. The panel with this honeycomb structure is only available in 38mm and 50mm thicknesses and also does not allow for the direct application of edge banding to the individual pieces without gluing a backing strip to the edge banding in place of the honeycomb structure, especially for edge banding less than 2mm thick.The presence of these particularities is a major drawback in the field of layout and furnishing, especially for the manufacture of furniture.

[0008] Construction modules made from corrugated and / or honeycomb cardboard are also known. However, these modules are covered with a film coating, making them airtight and watertight, without allowing for the finishing options of the various wood-based panels. They are also well-defined modules, not panels from which different pieces are cut for machining in various applications. They are very thick and are not designed for use in interior design, decoration, or furniture. They are specifically designed for building construction.

[0009] Corrugated Cardboard Core (CCC) or 3C, according to the invention, consists of wood-based facings, such as MDF (Medium Density Fibre) panels or particleboard, chipboard, melamine, etc., or OSB (Oriented Strand Board) panels or standard plywood panels, with raw or decorative finishes, and a corrugated cardboard core made from 100% recycled fibers, assembled by gluing or any other suitable technique.

[0010] The panels were designed to utilize corrugated cardboard sheets for their ecological qualities and properties in interior design and furniture, combining them with existing wood-based materials to make them lighter and more eco-friendly, while preserving their original applications. Not only does the design of these new materials perfectly meet expectations, but it also innovates upon existing standard panels by offering the sound, acoustic, and thermal properties of corrugated cardboard and resolving the drawbacks associated with other existing materials.

[0011] The combination of wood-based panels with a corrugated cardboard core makes it possible to obtain materials with the same surface appearance as ordinary standard panels of the same type and thickness, but considerably lighter, up to 50% for certain thicknesses and combinations, thanks to the air voids created by the undulations of the corrugated cardboard inside the different sheets of corrugated cardboard, which constitute the said core of the CCC panel.

[0012] These same air gaps reduce the raw material required for manufacturing the panels by 20 to 84% (excluding paperboard) compared to standard panels of the same type and thickness. This design avoids cutting down new trees and reducing CO2 emissions into our atmosphere.

[0013] The use of bio-based binders for assembling fibers, particles, strips, chips or wood sheets together, and bio-based wood glues for gluing superimposed layers of corrugated cardboard sheets, facings, interleaved layers and decorative or kraft paper sheets guarantees a healthy finished product, without the addition of formaldehyde.

[0014] The manufacture of 3C panels from only recycled wood, such as residues from unused trees and old furniture for the facings and interlayers, and recycled cardboard for the core, contributes to an eco-responsible approach with 100% recycled and recyclable materials.

[0015] The core, depending on the length x width dimensions of the facings to which it is attached, consists of one or more layers of single, double, or triple-wall corrugated cardboard made from cellulose fibers, itself created from wood or recycled cardboard and paper. A single-wall corrugated board is composed of two flat papers held equidistant by gluing a corrugated paper layer, thus creating air gaps, the thickness of which can vary from 1.4 mm to 4.9 mm. A double-wall corrugated board is composed of three flat papers held equidistant by gluing two corrugated papers, thus creating air gaps in two layers, the thickness of which can vary from 4.2 mm to 8 mm. A triple corrugated sheet is composed of four flat papers held at equidistant intervals by gluing three corrugated papers, thus forming air gaps on three layers, the thickness of which can vary from 13mm to 15mm±.The various layers of said panels are joined together, with the corrugations parallel or perpendicular to the width, by gluing or any other suitable technique, according to the desired quantity and variety. They are then pressed, with or without heating and light pressure, to maintain the defined thickness of the core, which corresponds to the total defined thickness of the finished CCC or 3C panel that the core will constitute, minus the thicknesses of the facings that make up the CCC panel. The panels can be joined by overlapping them along the direction of the corrugations, but also by reversing them, preferably by alternating them regularly, so that the corrugations intersect at 90°. This technique increases the strength and stability of the CCC panels.

[0016] The core is then integrated into the manufacturing process of the various standard facings or panels and / or assembled, by gluing or any other suitable technique, to the wood-based facings to which it is associated, on both sides with one of its two faces outside the underside of the facing face a and the second opposite face outside the underside of the facing face b. The assembly is pressed with or without heating and slight pressure, so as to respect the desired total finished thickness of the CCC wood-based panel thus formed, taking into account the remaining manufacturing steps to obtain a material with two finished surfaces.

[0017] However, the assembly process of the central corrugated cardboard core and the associated facings can also be carried out in such a way that the different layers of single, double or triple fluted corrugated cardboard sheets, which constitute said core, and said facings are made together, in a continuous line and / or in the same step.

[0018] The various facings, depending on the type of wood-based material and for each combination, are manufactured according to their respective composition and adapted to the design, or are sourced from standard, unfinished panels that have reached the sanding and calibration stage. These panels are then sanded and calibrated once assembled with the corrugated cardboard core, in standardized or customized variable length x width formats, with thicknesses ranging from 3 to 12 mm+ depending on their type, and are made from natural or recycled wood. They can be ordinary, water-repellent, or fire-retardant. The various standard panels used as facings remain unchanged and retain their original properties and appearance. Their material type defines the different variations within the CCC or 3C range of wood-based panels.

[0019] The range of MDF CCC (Medium Density Fibre Corrugated Cardboard Core) panels consists of facings of agglomerated wood fibers or standard, high-density MDF, 3 or 6mm± thick, defined according to the total thickness of the MDF CCC panel they constitute, assembled with a 100% recycled and recyclable corrugated cardboard core. The said range of CCC MDF panels also allows medium density facings of 8 or 10 or 12mm± thickness for the thicker CCC MDF panels and offers materials of different total thicknesses, from 9 to 100mm and more, with two dense, very smooth surfaces perfectly suited to the many coatings: paint, primer, lacquer, varnish, melamine coating, decorative or kraft paper, wood veneer, laminate veneer, various veneers, with a wide choice of finishes, decors and derivative products, such as: shelves, cabinet fronts, bookcases and many others.

[0020] The range of particleboard (chipboard, commonly used name for raw panels, or melamine, commonly used name for decorative panels covered with a decorative paper sheet impregnated with melamine resin on both sides) CCC (Corrugated Cardboard Core) consists of facings of particleboard and wood chips agglomerated or in standard particleboard, of 4 or 8mm± thickness defined according to the total thickness of the particleboard (chipboard or melamine) CCC they constitute, assembled with a 100% recycled and recyclable corrugated cardboard core.The CCC range also allows for facings of 10 or 12mm± thickness for CCC high-thickness particleboard (chipboard or melamine) and offers materials of different total thicknesses, from 9 to 100mm and more, with two finely sanded surfaces perfectly suited to numerous coatings: paint, primer, lacquer, varnish, melamine coating, decorative paper or kraft paper, wood veneer, laminate veneer, various veneers, with a wide choice of finishes, decors and derivative products, such as: worktops, tabletops, splashbacks, shelves, cabinets, cabinet fronts, cupboards, dressing rooms, cupboard doors, shelves, bookcases and many others.

[0021] The OSB CCC (Oriented Strand Board Corrugated Cardboard Core) panel range consists of facings of standard, medium-density OSB or strand board, available in thicknesses of 6, 9, or 12 mm±, depending on the overall thickness of the OSB CCC panel. These facings are bonded to a 100% recycled and recyclable corrugated cardboard core. This OSB CCC panel range offers materials in various overall thicknesses, from 15 mm to 200 mm and more, with two elegant surfaces perfectly suited to a wide range of finishes (paint, varnish, stain, oil, etc.) and derivative products, such as floor panels, interior partitions, and many others.

[0022] The CCC (Corrugated Cardboard Core Plywood) range consists of veneers of glued wood or standard, low-density plywood, available in thicknesses of 3, 5, 8, 10, or 12 mm±, depending on the overall thickness of the CCC plywood panel. These veneers are bonded to a 100% recycled and recyclable corrugated cardboard core. This range of CCC plywood panels offers materials in various overall thicknesses, from 12 mm to 200 mm and more, with two sanded surfaces perfectly suited for numerous coatings: paint, varnish, or stain. They can be finished with wood veneer, laminate veneer, or melamine or decorative coatings, with a wide selection of finishes, designs, and related products, such as interior door panels, interior partitions, and many others.This range is duplicated in a range of CCC (Corrugated Cardboard Core Wood Panels) wood panels with a composition of facings in noble wood sheets or covered with a wood panel in strips, assembled using a D3 glue without formaldehyde and without VOCs, of low thicknesses so as to offer derived products with a raw, oiled or varnished finish, such as: worktops, table tops, shelves and many others.

[0023] The process of assembling different layers of materials superimposed together to create a single-piece building material offers a range of CCC panels with diverse and varied combinations.Thus, the panels in the 3C range have variants following the same concept, with facings derived from wood of identical or different composition and / or in standard panels that have reached the final stage of manufacture, with two surfaces with a finish, identical or different, the finish being: raw, pre-painted, lacquered, varnished, with melamine coating, decorative paper or kraft, laminated veneer or a sheet of wood veneer, with counterbalanced or unbalanced undersides, lightly sanded for better adhesion, assembled and glued on both sides of the said corrugated cardboard core made up, with one of its two faces outside the underside of the facing face a and the second opposite face outside the underside of the facing face b, with or without an interleaved layer.In this way, one can obtain, for example and after assembly of the different layers, a CCC panel with two surfaced outer surfaces, white melamine or decor, or a surfaced CCC panel, one face in white melamine and the second face in raw MDF.

[0024] The invention of combining said corrugated cardboard with various wood-derived panels offers a wide choice of materials, varied or not, with different properties, with variable formats and thicknesses, multiple combinations of finishes, decorations, and derivative products for all furniture manufacturing, layout or furnishing, decoration and interior joinery, and construction projects.

[0025] Technically, these materials are very easy to machine due to their low weight and the thinness of the facings and interleaved panels, which have varying densities of fibers or particles. Thanks to these same properties, the products in the CCC panel range reduce premature wear of the blades and tools used to machine them, unlike solid wood and wood-based panels.

[0026] The 3C MDF range also offers the possibility of laser cutting the panels to shape. Its various thicknesses and very light weights, with a raw or varnished finish that allows the edge of the corrugated cardboard to be seen, make it an ideal product for decoration, signage, lettering, etc.

[0027] 3C MDF panels can also be easily engraved with a laser or router with a maximum depth of 2.5mm to 5mm depending on the thickness of the facings.

[0028] The present invention solves the drawback, mentioned in paragraph 7, concerning lightweight panels with a honeycomb structure, which are only available in 38mm and 50mm thicknesses and require the addition of an edge support strip less than 2mm thick before edge banding. Indeed, the CCC panel can be marketed from 9mm thick, and the edges of said CCC panels are finished by direct banding after cutting or machining, and with all types of edge banding with a thickness of 0.4mm to 2mm and more, such as thermoplastic, melamine, laminate, real wood, kraft paper, MDF edgebanding, depending on the different finishes desired or can remain raw, thanks to the different layers of paper, which make up the single, double or triple fluted corrugated cardboard sheets and which constitute the core of said CCC panels, which serve as a point of contact and support for the edges and the different air voids serve as a space for grip and adhesion of the glue with the papers and the edge, which once dry hardens and forms a support sufficiently rigid and straight for holding the glued edge.

[0029] The 3C MDF panels with MDF edges, which are non-existent and designed for the concept, from 0.8 to 2mm± thick, have an identical surface finish on the faces and edges, unlike ordinary MDF panels, mentioned in paragraph 4, in order to reduce the varnishing, lacquering or painting steps on the edges.

[0030] The edges of CCC wood-based panels can also be machined, single-sided or double-sided, into quarter-round, half-round, or any other rounded profile to be covered with a postformable laminate sheet, particularly for kitchen or bathroom worktops. Similarly, they can be covered with decorative paper or melamine coating for kitchen, bathroom, living room, and other furniture fronts.

[0031] The CCC panel range offers superior sound and acoustic performance compared to standard wood or wood-based panels, thanks to the air voids created by the corrugations of the paper within the individual sheets. The sound absorption coefficient varies depending on the thickness of the different combinations and characteristics of the panels in the CCC range.

[0032] This acoustic insulation quality allows the CCC range of materials and derived products to meet the demands of those who want a product with enhanced sound insulation and acoustic attenuation in accordance with regulations, respecting their implementation, such as soundproof interior doors, partitions, floors, false ceilings, etc.

[0033] The acoustic properties of corrugated cardboard will have a very beneficial impact in rooms where all the furniture or elements made with panels from the 3C range are placed. Each of these elements will have the ability to absorb various ambient noises from the rooms in which they are located.

[0034] The single, double, or triple fluting of the corrugated cardboard sheets traps air and provides the CCC range of panels with high thermal resistance in addition to sound and acoustic insulation. This insulation is enhanced by the thickness of the CCC panel's core; the thicker the layers of corrugated cardboard, the greater the insulation. The substantial thicknesses of the 3C OSB and 3C plywood panels are perfectly suited for the construction, extension, and renovation of houses or buildings, thanks to the combined thermal and acoustic performance of the cardboard.

[0035] Corrugated cardboard has good fire resistance; it does not ignite, but it burns. Thanks to this quality, a panel with a corrugated cardboard core and fire-retardant facings can be manufactured with M1 fire rating and Euroclass B certification, subject to studies conducted by the relevant authorities. This classification allows the use of CCC panel ranges, with fire-retardant facings, in conditions requiring M1-rated panels in dry environments, particularly for wall cladding in commercial spaces.

[0036] This invention of wood-based panels with a corrugated cardboard core allows all types of conventional assemblies for layout, furniture and joinery, unlike the honeycomb structure panels mentioned in paragraph 7, such as: wood strips, 45° cuts with or without wood strips, dowels, tongue and groove and false tongues, edge strips, etc., thanks, as with the edges, to the different layers of paper with resistant properties, which make up the single, double or triple fluted corrugated cardboard sheets and which constitute the core of said CCC panels, which serve as a point of contact and support for the different wood or wood-based assembly pieces and the different air voids serve as a space for the glue to grip and adhere to the papers and the said different assembly pieces, which once dry hardens and bonds the whole to obtain a compact, solid and resistant assembly.The said CCC panels allow the different panel pieces to be assembled together, with the different mechanical assemblies, such as: eccentric clamping fittings, worktop assembly fittings, etc., thanks to the vertical compression resistance capacities of the said different layers of flat cardboard paper, the density and thicknesses of the facings which, with the said core, constitute the said CCC panels, and the different layers interleaved for assembly by screwing, nailing and stapling.

[0037] The ranges of particleboard and MDF panels with a corrugated cardboard core also address the drawbacks of traditional particleboard and MDF, mentioned in paragraph 3. Indeed, the assembly of the corrugated cardboard core, by layering different sheets, allows for the insertion of a wood-derived layer, or a standard MDF, particleboard, OSB, or plywood layer between the layers of these corrugated cardboard sheets, preferably in the center of the core. This layer, with a thickness of 3 to 8 mm+, is chosen according to the length x width dimensions of the core to which it is attached, and is available in high or medium density. For thicker panels, multiple layers can be strategically positioned according to their intended use. This technique allows the air gaps in the corrugated cardboard flutes to absorb the swelling of the panels caused by screwing, nailing, or stapling, while maintaining sufficient strength for a secure assembly, thanks to the properties of the cardboard.In this way, the facings are spared from said swelling and cracks at the ends and retain a very good surface condition.

[0038] To define the panels of the said different ranges of MDF, particle, OSB, CCC or 3C plywood panels with particular properties, such as: panels with water-repellent or fire-retardant facings and panels with one or more interleaved layers, they will be assigned after the last letter C (Core) the first letter of the word (in English) of their distinctive characteristics, i.e. reciprocally: W (Water repellent) or F (Fire retardant) or R (Reinforced).

[0039] Corrugated cardboard is economically attractive due to its low cost compared to wood or wood derivatives. Combining it with wood-based materials results in substantial savings for CCC range panels compared to standard panels.

[0040] Corrugated cardboard core panels are intended for indoor use in dry environments, in all types of applications, including: - Interior design: furniture and decoration for shops, offices and homes, reception areas, stands, wall coverings, lettering, etc. - Furniture: kitchens, bathrooms, cupboards, dressing rooms, shelves, cabinets, trays, bookcases, sliding doors, tables, worktops, etc. - Joinery: interior doors, flooring, partitions (insulated or not), etc. - Interior fittings for all types of vehicles: vans, campervans, motorhomes, caravans, trailers, utility vehicles, boats, ships - Timber framing: construction, extension and renovation of a house or building - Toys and other…

[0041] The ranges of panels with water-repellent facings can be used indoors and in humid environments.

[0042] The present invention is not limited to the few examples of drawings described and shown below. The CCC panel range offers a wide choice of materials and products, with formats and thicknesses in multiple and varied combinations, finishes, and decorations, also allowing all types of conventional joinery assemblies for all interior design or decoration projects, furniture manufacturing, joinery, and construction.

[0043] This shows a partial view of a panel offered by the various ranges of wood-based panels with a corrugated cardboard core (1). It consists of a corrugated cardboard core (2) and wood-based facings (1a) and (1b), either MDF, particleboard, OSB, plywood, or others, with thicknesses corresponding to each and described in Figures 3 to 6. The outer faces (1c), (1d) of the facings can have a raw finish or any type of finish suitable for the different facings listed in Figures 3 to 6. The core of the panel shown (1) is made up of four single-flute sheets (2a) or two double-flute sheets (2b) stacked together; however, the core is constructed according to the variable finished thicknesses (E) of the panel ranges and their different combinations.

[0044] Figure 1 shows a partial view of three single-wall corrugated cardboard sheets (2e) (2a), assembled by overlapping, with the central sheet inverted along the direction of the corrugations so that the corrugations intersect at 90°. The same intersection is applied to double- and triple-wall sheets. This technique increases the strength and stability of the panels.

[0045] This shows a truncated cross-section of a CCC MDF panel (3) composed of 3mm MDF facings (3a, 3b) and a corrugated cardboard core (2), itself composed of two 6.5mm double-wall corrugated sheets (2b), to form a panel with a total thickness (E1) of 19mm. The surfaces (3c, 3d) of the facings can have a raw, pre-painted, melamine or laminate finish, wood veneer or other, according to the manufacturer's color chart.

[0046] This shows a truncated cross-section of a CCC particleboard panel (4) composed of 8mm particleboard facings (4a, 4b) and a corrugated cardboard core (2), itself composed of two 8mm double-wall corrugated sheets (2b) and a 3mm single-wall corrugated core (2a), forming a panel with a total thickness (E2) of 35mm. The surfaces (4c, 4d) of the facings can have a raw, melamine, or laminate finish, wood veneer, or other finishes, according to the manufacturer's color chart.

[0047] This shows a truncated cross-section of a CCC OSB panel (5) composed of 6mm OSB facings (5a, 5b) and a corrugated cardboard core (2), itself composed of two 3mm single-flute sheets (2a) and a 4mm single-flute central sheet (2a), forming a panel with a total thickness (E3) of 22mm. The surfaces (5c, 5d) of the facings have a raw or varnished finish.

[0048] This shows a truncated cross-section of a CCC plywood panel (6) composed of 5mm plywood facings (6a, 6b) and a corrugated cardboard core (2), itself composed of two 13mm triple-flute sheets (2c) and a 4mm single-flute central sheet (2a), forming a panel with a total thickness (E5) of 40mm. The surfaces (6c, 6d) of the facings may have a raw, pre-painted, melamine or laminate finish, wood veneer or other, according to the manufacturer's color chart.

[0049] This shows a truncated cross-section of a CCCR (3R) MDF panel composed of 3mm MDF facings (3a, 3b) and a corrugated cardboard core (2), itself composed of two 5mm single-flute corrugated sheets (2a) and an interlayer of 3mm MDF (2d), to form a panel with a total thickness (E1) of 19mm. The surfaces (3c, 3d) of the facings can have a raw, pre-painted, melamine or laminate finish, wood veneer or other finishes, according to the manufacturer's color chart.

[0050] This shows a truncated cross-section of a variant (7) of CCC panels (1) composed of a 3mm MDF facing (7a), a 4mm melamine facing (7b) with a finish of your choice, and a corrugated cardboard core (2), itself composed of four 3mm single-flute corrugated sheets (2a), to form a panel with a total thickness (E1) of 19mm. The surface (7c) of the MDF facing (7a) can be left unfinished, ready to receive a varnish application, and the surface (7d) of the melamine facing (7b) can have a white melamine finish. In this way, a piece of furniture can be designed with a completely white melamine interior and varnished MDF exterior surfaces. This avoids the need to varnish the entire interior of the furniture.

[0051] The various wood-based panels with a CCC corrugated cardboard core (1) allow edge banding by direct veneering after cutting or machining of said panels with all types of edges. The different layers of flat cardboard (2f) and corrugated cardboard (2g), which make up the single (2a), double (2b) or triple (2c) fluted corrugated cardboard sheets and which constitute the core of the panel (2), serve as contact and support points (2i) for the different edges: MDF edge (C1), thermoplastic ABS edge from 0.4mm to 2mm thick (C2), kraft paper edge 0.5mm thick (C3), postformable laminate edge 0.8mm thick (C4). The various air gaps (2h) serve as the contact and adhesion space for the glue (2j) with the papers and edges (C1 to C4), which, once dry, hardens and forms a sufficiently rigid and straight support for holding the glued edges (C1 to C4). Some of these gaps are shown below.

[0052] This shows a truncated cross-section of a CCC MDF shelf (3) with a total thickness (E1) of 19mm, with an MDF edge banding (C1). The edges can be edge banding applied directly after cutting or machining.

[0053] This shows a partial view of the CCC MDF panel (3) representing one face and the MDF-veneered edge (C1). It can be seen that the surface condition of the faces and edges is identical and ready to receive a varnished, lacquered, or painted finish of choice, without any additional preparation work.

[0054] The various wood-based panels with a corrugated cardboard core (1) can also be produced in different formats, thicknesses, and finishes, with various combinations. The following are some examples.

[0055] This shows a truncated cross-section of a CCCW particleboard panel (4W) consisting of 8mm thick water-resistant chipboard faces (4aw, 4bw) and a corrugated cardboard core (2) to form a worktop with a total thickness (E4) of 38mm, with straight edges including the front edge (C2). The panel is faced with a laminated surface and a balancing underside (4d) of kraft paper. The back edge (C3) is edged with kraft paper edge banding, and the front edge (C2) is edged with ABS thermoplastic edge banding.

[0056] This shows a truncated cross-section of a CCCW particleboard panel (4W) consisting of 8mm thick water-resistant chipboard faces (4aw, 4bw) and a corrugated cardboard core (2) to form a worktop with a total thickness (E4) of 38mm, with straight edges except for the front edge (C4), which is machined into two quarter-rounds (r1) to receive a post-formable coating. The panel is faced with a post-formed laminate face (4c) that overlaps the front edge (C4) and has a slight return on the underside (4d). The underside of the panel is counterbalanced (4d) with kraft paper. The rear edge (C3) is edged with kraft paper.

[0057] This shows a truncated cross-section of a CCC OSB panel (5) consisting of 6mm OSB facings (5a, 5b) and a corrugated cardboard core (2e), itself composed of two 3mm single-flute sheets (2a), a 4mm single-flute central sheet (2a) with reversed corrugations, and a 10mm thick OSB tongue (2l) along one length and one width, to form a floor panel with a total thickness (E3) of 22mm. The second length and width are machined with a groove the thickness of the core and 9mm deep (2m) to receive a tongue from another panel. The surfaces (5c, 5d) of the facings (5a, 5b) are unfinished and ready to receive paint, varnish, or stain.

[0058] This shows a truncated cross-section of a CCC plywood panel (6) consisting of 5mm plywood facings (6a, 6b) and a corrugated cardboard core (2), itself composed of two 13mm triple-flute sheets (2c), a 4mm single-flute central sheet (2a) and a solid perimeter frame (2k), forming a door leaf with a total thickness (E5) of 40mm. The surfaces (6c, 6d) of the facings (6a, 6b) are pre-painted.

[0059] Various wood-based panels with a corrugated cardboard core (CCC) allow for all types of joinery. As with edge banding, the different layers of resistant paper that make up the single, double, or triple-wall corrugated cardboard sheets and form the core of these CCC panels serve as points of contact and support for the various wood or wood-based components. The air gaps provide space for the adhesive to bond with the paper and the components. Once dry, the adhesive hardens, bonding the entire assembly to create a compact, solid, and resistant joint. These panels are the main ones used in interior design, furniture making, and joinery.

[0060] This shows a truncated cross-section of two CCC MDF panels (3), consisting of 3mm thick MDF facings (3a, 3b) and a corrugated cardboard core (2), to form panels with a total thickness (E1) of 19mm. The two panels are joined together at a 90° angle by gluing, with a 45° cut, using wooden strips of L56mm x W22mm x E4mm (2n).

[0061] This figure shows a truncated cross-section of two panels from the CCC range (1), consisting of facings (3a to 7a, 3b to 7b) 4 mm or ± thick and a corrugated cardboard core (2), to form panels of variable total thickness (E). The two panels are joined together at a 90° angle by gluing with wooden strips measuring L56 mm x W22 mm x E4 mm (2n). The figure shows an end joint of the panels with edge banding and also demonstrates that the joint can be made at any point on the panels.

[0062] This figure shows a truncated cross-section of two panels from the CCC range (1), consisting of facings (3a to 7a, 3b to 7b) 4 mm or ± thick and a corrugated cardboard core (2), forming panels of variable total thickness (E). The two panels are joined together at a 90° angle by gluing with 8 mm diameter and 30 mm wide dowels (2o). The figure shows an end joint of the panels with edge banding and also demonstrates that the joint can be made at any point on the panels.

[0063] This figure presents a truncated cross-section of two panels from the CCC range (1), consisting of facings (3a to 7a, 3b to 7b) 4 mm or ± thick and a corrugated cardboard core (2), to form panels of variable total thickness (E). The two panels are joined together at a 90° angle using dowels and mechanical fasteners such as eccentric housings (2p). This assembly method is preferred for flat-pack furniture designed for assembly and disassembly. The figure shows an end joint of panels with edge banding and also demonstrates that the joint can be made at any point on the panels.

[0064] This shows a truncated cross-section of two panels from the CCCR range (1R), consisting of facings (3a to 7a, 3b to 7b) 4 mm or ± thick and a corrugated cardboard core (2) with an interleaved layer (2d) sandwiched between two single-flute MDF, chipboard, or OSB panels (2a), to form panels of varying total thickness (E). The two panels are joined together at a 90° angle by gluing and screwing (2q). This technique allows the air gap (2h) in the various corrugations of the corrugated cardboard to absorb the swelling of the panels caused by screwing, nailing, or stapling, while maintaining sufficient strength for a secure assembly, thanks to the properties of the cardboard, and preserving the surface finish of the facings (3a to 7a, 3b to 7b). The figure shows an end assembly of panels with edge veneer and it also shows that the assembly can be done anywhere on the panels.

[0065] This shows a truncated cross-section of two CCCW particleboard panels (4W) consisting of 8mm thick water-resistant chipboard faces (4aw, 4bw) and a corrugated cardboard core (2) to form a worktop with a total thickness (E4) of 38mm. The panel is faced with laminate (4c) on one side and kraft paper on the underside (4d) for balancing. The two panels are joined end-to-end by gluing using wooden strips and mechanical fasteners such as cap screws (2s).

[0066] This shows a truncated cross-section of two panels from the CCC range (1), made up of facings from the CCC range (3a to 7a, 3b to 7b) of 4mm or ± thickness and a corrugated cardboard core (2), to form panels of variable total thickness (E). The two panels are joined end-to-end by gluing 18mm wide and 5mm thick plywood (2t) using a tongue and groove joint.

[0067] This presents a partial view of a wood-derived panel with a corrugated cardboard core (1).

[0068] Present three single fluted corrugated cardboard (2e) plates (2a), assembled by superposition and whose central plate is reversed according to the direction of the corrugations.

[0069] This presents a truncated section of a CCC MDF panel (3) composed of MDF facings (3a, 3b) and a corrugated cardboard core (2) composed of two double fluted plates (2b).

[0070] This presents a truncated section of a CCC particle board (4) composed of particle facings (4a, 4b) and a corrugated cardboard core (2) composed of two double fluted plates (2b) and a single fluted central plate (2a).

[0071] This presents a truncated section of an OSB CCC panel (5) composed of OSB facings (5a, 5b) and a corrugated cardboard core (2) composed of two single flute plates (2a) and a single flute center plate (2a).

[0072] This shows a truncated section of a CCC plywood panel (6) composed of plywood facings (6a, 6b) and a corrugated cardboard core (2) composed of two triple flute plates (2c) and a single flute central plate (2a).

[0073] This presents a truncated section of a CCCR MDF panel (3R) composed of MDF facings (3a, 3b) and a corrugated cardboard core (2) composed of two single flute plates (2a) and an interleaved MDF layer (2d).

[0074] This presents a truncated section of a variant (7) of CCC panels (1) composed of an MDF facing (7a), a melamine facing (7b) and a corrugated cardboard core (2) composed of four single flute plates (2a).

[0075] This presents a truncated section of a CCC (3) MDF shelf with an MDF (C1) veneered edge.

[0076] Presents a CCC MDF panel (3) representing one face and the MDF veneered edge (C1).

[0077] This presents a truncated section of a CCCW (4W) water-resistant particleboard laminate worktop, consisting of water-resistant chipboard facings (4aw, 4bw) and a corrugated cardboard core (2) with ABS straight front edge (C2).

[0078] This presents a truncated section of a post-formed laminated worktop made of CCCW (4W) water-resistant particle board, consisting of water-resistant chipboard facings (4aw, 4bw) and a corrugated cardboard core (2) with profiled front edge (C4).

[0079] This presents a truncated section of a floor slab made of OSB CCC panel (5), with two rough surfaces (5c, 5d), consisting of OSB facings (5a, 5b) and a corrugated cardboard core (2e) with OSB grooves (2m) and tongues (2l).

[0080] This presents a truncated section of a door leaf made of CCC plywood panel (6), with two pre-painted surfaces (6c, 6d), consisting of plywood facings (6a, 6b) and a corrugated cardboard core (2) with a solid frame around the perimeter (2k).

[0081] This shows a cross-section of two CCC MDF panels (3), consisting of MDF facings (3a, 3b) and a corrugated cardboard core (2), assembled together, at a 90° angle, by gluing, at a 45° cut, using wooden strips (2n).

[0082] This shows a cross-section of two CCC panels (1), consisting of facings (3a to 7a, 3b to 7b) and a corrugated cardboard core (2), assembled together, at a 90° angle, by gluing using wooden strips (2n).

[0083] This shows a cross-section of two CCC panels (1), consisting of facings (3a to 7a, 3b to 7b) and a corrugated cardboard core (2), assembled together, at a 90° angle, by gluing using wooden strips (2n).

[0084] This shows a cross-section of two CCC panels (1), consisting of facings (3a to 7a, 3b to 7b) and a corrugated cardboard core (2), assembled together, at a 90° angle, by means of dowels and eccentric housings (2p).

[0085] This presents a cross-section of two CCCR panels (1R), consisting of facings (3a to 7a, 3b to 7b) and a corrugated cardboard core (2) with an interleaved layer (2d) between two single flute plates (2a), assembled together, at a 90° angle, by gluing and screwing (2q).

[0086] This shows a partial cross-section of two CCCW particleboard panels (4W), consisting of water-resistant chipboard facings (4aw, 4bw) and a corrugated cardboard core (2), joined together, end to end, by gluing with wooden strips and cap screws (2s).

[0087] This shows a partial cross-section of two CCC panels (1), consisting of facings (3a to 7a, 3b to 7b) and a corrugated cardboard core (2), assembled together, end to end, by gluing in groove and false tongue (2t).

Claims

Wood-based panel (1), such as a Medium Density Fibre (MDF) panel, a raw or melamine-faced particle board also called chipboard or melamine respectively, an OSB (Oriented Strand Board) panel, a plywood panel, made up of fibres, particles, lamellae, chips or sheets of natural wood, agglomerated or glued, in formats of variable length x width x thickness (E), characterized in that its core is made of corrugated cardboard (2) made up of single (2a), double (2b) or triple (2c) fluted corrugated cardboard sheet(s), made from 100% recycled fibres. Wood-based panel (1) according to claim 1, characterized in that it consists of a corrugated cardboard core (2) and facings (1a, 1b) of 3 to 12mm thickness made of agglomerated fibers, particles, lamellae and / or wood chips or glued wood sheets. Wood-based panel (1) according to any one of claims 1 and 2, characterized in that said facings (1a, 1b), of identical standardized or adapted length x width x thickness of 3 to 12mm, are raw standard wood-based panels that have reached the sanding-calibration stage. Wood-derived panel (1) according to the preceding claims, characterized in that said facings (1a, 1b) are made from recycled wood. Wood-derived panel (1) according to claims 1 to 3, characterized in that said facings (1a, 1b) are made from natural wood. Wood-based panel (1) according to the preceding claims, characterized in that said corrugated cardboard core (2) is made up of one or more single (2a), double (2b) or triple (2c) fluted corrugated cardboard sheets, made from cellulose fibers created from wood, which are assembled by superimposing them following the direction of the corrugations or reversing them, by regular alternation, so that the corrugations cross at 90° (2e). Wood-derived panel (1) according to the preceding claims, characterized in that said corrugated cardboard sheets (2a, 2b, 2c) are made of cellulose fibers created from old recycled cardboard and paper. Wood-based panel (1) according to the preceding claims, characterized in that it uses bio-based binders for the assembly of fibers, particles, strips, chips or wood sheets, and bio-based glues for the bonding of superimposed layers of corrugated cardboard sheets (2a, 2b, 2c), facings (1a, 1b), interleaved layers (2d) and veneer sheets. Wood-based panel (1) according to the preceding claims, characterized in that the facings (3a, 3b) are made of agglomerated wood fibers or standard MDF, high density, 3 or 6 mm thick or medium density, 8, 10, 12 mm thick, assembled with said corrugated cardboard core (2), defining a range of MDF panels with a corrugated cardboard core (3). Wood-based panel (1) according to claims 1 to 8, characterized in that facings (4a, 4b) are made of particleboard and wood chips agglomerated or particleboard or agglomerated or melamine standard, raw or covered with a decorative paper sheet impregnated with melamine resin, of 4 or 8mm or 10, 12mm thickness, assembled with said corrugated cardboard core (2), defining a range of particleboard or agglomerated or melamine panels with a corrugated cardboard core (4). Wood-based panel (1) according to claims 1 to 8, characterized in that facings (5a, 5b) are made of standard medium-density agglomerated wood or OSB strips of 6 or 9 or 12mm thickness, assembled with said corrugated cardboard core (2), defining a range of OSB panels with a corrugated cardboard core (5). Wood-based panel (1) according to claims 1 to 8, characterized in that facings (6a, 6b) are made of glued wood sheets or standard low-density plywood of 3 or 5 or 8 or 10 or 12mm thickness, assembled with said corrugated cardboard core (2), defining a range of plywood panels with a corrugated cardboard core (6). Wood-based panel (1) according to claims 1 to 8, characterized in that facings (6a, 6b) are made of noble wood sheets glued or covered with a wood panel in strips, assembled with said corrugated cardboard core (2), defining a range of wood panels with a corrugated cardboard core. Wood-derived panel (1) according to any one of the preceding claims, characterized in that said facings (1a, 1b) are of different constitution (7a, 7b). Wood-based panel (1) according to any one of the preceding claims, characterized in that said facings (1a, 3a to 7a, 1b, 3b to 7b) are standard wood-based panels that have reached the final stage of manufacture. Wood-based panel (1) according to any one of the preceding claims, characterized in that said corrugated cardboard core (2) is made up of several corrugated cardboard sheets in which is intercalated one or more layers of wood-based material (2d) or of MDF or of chipboard or of OSB or of standard plywood, of high or medium density, of 3 to 8mm thickness. Wood-derived panel (1) according to any one of the preceding claims, characterized in that said facings (1a, 3a to 7a, 1b, 3b to 7b) are water-repellent. Wood-derived panel (1) according to any one of the preceding claims, characterized in that said facings (1a, 3a to 7a, 1b, 3b to 7b) are fire-resistant. Wood-based panel (1) according to the preceding claims, characterized in that the edge treatment is done by direct veneering after cutting or machining and with all types of edges with a thickness of 0.4mm to 2mm, thanks to the different layers of paper (2f, 2g) which serve as a point of contact and support (2i) for the edges (C1 to C4) and the different air voids (2h) serve as a space (2j) for the grip and adhesion of the glue (C1 to C4), which once dry hardens and forms a rigid and straight support for holding the glued edge (C1 to C4). Wood-based panel (1) according to the preceding claims, characterized in that panels from the MDF CCC range (3) with MDF edges (C1), from 0.8 to 2mm thick, have an identical surface condition of the faces (3c, 3d) and edges (C1) so as to reduce the varnishing, lacquering or painting steps of the edges (C1). Wood-based panel (1) according to the preceding claims, characterized in that the edges of said wood-based panels (1, 4) are machined, single-sided or double-sided (C4), in quarter-round (C4), half-round or any other rounded profile to be covered with a postformable laminate sheet (C4), a paper or a decorative melamine coating. A method for manufacturing the corrugated cardboard core (2) of the wood-based panel (1) according to the preceding claims, characterized in that: - The corrugated cardboard core (2) consists of several layers of single (2a), double (2b), or triple (2c) fluted corrugated cardboard sheet made of cellulose fibers created from wood or recycled cardboard and paper; - The different layers of said sheets are joined together, with the corrugations parallel or perpendicular to the width, by superimposing them following the direction of the corrugations or reversing them, by regular alternation, so that the corrugations intersect at 90° (2e), by gluing, according to the desired quantities and variety; - The assembly is pressed, with or without heating, so as to maintain the defined thickness of said corrugated cardboard core (2) and corresponding to the defined total thickness (E) of the finished wood-based panel (1). This will constitute. Method of manufacturing the corrugated cardboard core (2) of the wood-based panel (1) according to the preceding claim, characterized in that one or more layers of wood-based material (2d) or MDF or chipboard or OSB or standard plywood, according to the length x width format of the core (2) to which they are assembled, of high or medium density, of 3 to 8mm thickness, are interleaved between the layers of corrugated cardboard (2a, 2b, 2c). A method for manufacturing the wood-based panel (1) according to claims 1 to 18 and 22 to 23, characterized in that: - The corrugated cardboard core (2) is made up of one or more single (2a), double (2b) or triple (2c) fluted corrugated cardboard sheets, which are assembled independently or in the same assembly step, in a continuous line; - Said corrugated cardboard core (2) is integrated into the manufacturing process of the various facings or standard panels and assembled by gluing to the wood-based facings to which it is associated, on both sides with one of its two external faces (2.1) to the underside of the facing face a (1a, 3a to 7a) and the second opposite external face (2.2) to the underside of the facing face b (1b, 3b to 7b).The various wood-derived facings and for each of the combinations, in standardized or adapted variable length x width formats x thickness from 3 to 12mm, are manufactured according to their respective composition and adapted to the concept, such as: fibers (3a, 3b), particles and chips (4a, 4b), agglomerated wood strips (5a, 5b) or glued wood sheets (6a, 6b), from natural or recycled wood. They can be ordinary, water-repellent or fire-retardant, of identical (1a, 3a to 6a, 1b, 3b to 6b) or different (7a, 7b) composition; - The whole is pressed with or without heating, then sanded-calibrated so as to respect the desired total finished thickness (E) of the wood-derived panel CCC(1, 3 to 7), thus constituted, taking into account the remaining manufacturing steps to obtain a material with two finished surfaces (1c, 3c to 7c, 1d, 3d to 7d). A method for manufacturing the wood-based panel (1) according to claims 1 to 18 and 22 to 23, characterized in that: - The corrugated cardboard core (2) is made up of one or more single (2a), double (2b) or triple (2c) fluted corrugated cardboard sheets, which are assembled independently or in the same assembly step; - Said corrugated cardboard core (2) is assembled by gluing to the wood-based panel facings to which it is associated, on either side with one of its two external faces (2.1) to the underside of the facing face a (1a, 3a to 7a) and the second opposite external face (2.2) to the underside of the facing face b (1b, 3b to 7b).The various wood-derived facings and for each of the combinations, in standardized or adapted variable length x width formats x thickness from 3 to 12mm, come from standard manufactured panels, raw, having reached the sanding-calibration stage, such as: high-density MDF (3a, 3b) of 3 or 6 mm thickness or medium-density MDF of 8, 10, 12mm thickness, particleboard or chipboard (4a, 4b) of 4 or 8mm or 10, 12mm thickness, medium-density OSB (5a, 5b) of 6 or 9 or 12mm thickness or low-density plywood (6a, 6b) of 3 or 5 or 8 or 10 or 12mm thickness, from natural or recycled wood.They can be ordinary, water-repellent or fire-retardant, of identical (1a, 3a to 6a, 1b, 3b to 6b) or different (7a, 7b) composition; - The whole is pressed with or without heating, then sanded-calibrated so as to respect the desired total finished thickness (E) of the wood-derived panel CCC(1,3 to 7), thus constituted, taking into account the remaining manufacturing steps to obtain a material with two finished surfaces (1c, 3c to 7c, 1d, 3d to 7d). A method for manufacturing the wood-based panel (1) according to claims 1 to 18 and 22 to 23, characterized in that: - The corrugated cardboard core (2) is made up of one or more single (2a), double (2b) or triple (2c) fluted corrugated cardboard sheets, which are assembled independently or in the same assembly step; - Said corrugated cardboard core (2) is assembled by gluing to the wood-based panel facings to which it is associated, on either side with one of its two outer faces (2.1) to the underside of the facing face a (1a, 3a to 7a) and the second opposite outer face (2.2) to the underside of the facing face b (1b, 3b to 7b), the undersides of which are slightly sanded.The various wood-derived facings and for each of the combinations, in standardized or adapted variable length x width formats x thickness from 3 to 12mm, come from standard manufactured panels, which have reached the final stage of manufacture, such as: high-density MDF (3a, 3b) of 3 or 6 mm thickness or medium-density MDF of 8, 10, 12mm thickness, particleboard or chipboard or melamine (4a, 4b) of 4 or 8mm or 10, 12mm thickness, medium-density OSB (5a, 5b) of 6 or 9 or 12mm thickness or low-density plywood (6a, 6b) of 3 or 5 or 8 or 10 or 12mm thickness, from natural or recycled wood.They can be ordinary, water-repellent or fire-retardant, of identical (1a, 3a to 6a, 1b, 3b to 6b) or different (7a, 7b) composition; - The whole is pressed with or without heating, so as to respect the desired total finished thickness (E) of the wood-derived panel CCC(1, 3 to 7) thus formed, on both surfaces with an identical (1c, 3c to 6c, 1d, 3d to 6d) or different (7c, 7d) finish. Use of the wood-based panel (1) according to claims 1 to 21, characterized in that said wood-based panels are intended for use indoors and in dry environments or in humid environments for panels with water-repellent facings, in all types of fields, namely: Layout, Furniture, Joinery, Interior fitting of all types of vehicles, Toys and others.

Images