Title:
Lightweight man-made board
Kind Code:
A1


Abstract:
A lightweight board has a face board, a base board, a center layer positioned between the face board and the base board, and a frame structure encircling the center layer between the face board and the base board, with the frame structure having a plurality of tubular sections. The face board, the base board and the center layer are combined to form a single unit.



Inventors:
Wang, Xichuan (La Habra Heights, CA, US)
Application Number:
11/378905
Publication Date:
10/11/2007
Filing Date:
03/17/2006
Assignee:
Panel Resources, Inc.
Primary Class:
International Classes:
E04C2/32
View Patent Images:



Primary Examiner:
QUAST, ELIZABETH A
Attorney, Agent or Firm:
Chen Yoshimura LLP (Sunnyvale, CA, US)
Claims:
What is claimed is:

1. A board comprising: a face board; a base board; a center layer positioned between the face board and the base board; and a frame structure encircling the center layer between the face board and the base board, the frame structure having a plurality of tubular sections fixed to the face board and the base board, wherein the face board, the base board and the center layer are combined into a single unit.

2. The board of claim 1, wherein a space defined between the face board and the base board is filled with a filler.

3. The board of claim 1, wherein a cavity is defined by the face board, the base board, and the frame structure, and the center layer further includes an intermediate board arranged in the cavity.

4. The board of claim 3, wherein the intermediate board is fixed in the cavity by support blocks that are connected to the face board and the base board.

5. The board of claim 3, further comprising a reinforcing board arranged between the intermediate board and the face board.

6. The board of claim 5, wherein the intermediate board and the reinforcing board are fixed to the face board and the base board by support blocks.

7. The board of claim 1, further comprising installation grooves formed in the face board.

8. The board of claim 1, further comprising installation grooves formed in the base board.

9. The board of claim 1, wherein the tubular sections of the frame structure are made of hollow plastic tubes.

10. The board of claim 2, wherein the filler is a light foam.

11. The board of claim 3, wherein the intermediate board is made of a medium density fiberboard, particleboard, or plywood.

12. The board of claim 4, wherein the support blocks are made of solid wood.

Description:

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to the technical field of man-made board materials, and in particular, to a type of lightweight man-made board.

2. Description of the Related Art

Man-made board materials currently available on the market include particleboard, medium density fiberboard, plywood, etc. Since these boards perform similarly to solid wood and are easy to process, they are widely used in furniture manufacturing, decoration, and other fields.

Unfortunately, these board materials suffer from some disadvantages which limit their use in some applications. For example, since these board materials are relatively heavy, when they are used to manufacture exhibition panels or other shelves that require repeated transportation, they are often unable to meet the transportation weight requirements. Therefore, the user will sometimes use hollow boards as a substitute. However, this causes another problem since these hollow boards are not strong and often become deformed because they cannot support the weight of the exhibited products placed on these shelves.

Thus, there still remains a need for a lightweight board material that is strong enough to support heavy weights.

SUMMARY OF THE INVENTION

Accordingly, the present invention is directed to a board structure that substantially obviates one or more of the problems due to limitations and disadvantages of the related art.

It is an object of the present invention to provide a board that is lightweight yet is strong enough to support heavy weights.

Additional features and advantages of the invention will be set forth in the descriptions that follow and in part will be apparent from the description, or may be learned by practice of the invention. The objectives and other advantages of the invention will be realized and attained by the structure particularly pointed out in the written description and claims thereof as well as the appended drawings.

In order to accomplish the objects of the present invention, the present invention provides a board having a face board, a base board, a center layer positioned between the face board and the base board, and a frame structure encircling the center layer between the face board and the base board, the frame structure having a plurality of tubular sections fixed to the face board and the base board, and the face board, the base board and the center layer are combined to form a single unit.

It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory and are intended to provide further explanation of the invention as claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cut-away perspective view of a board structure according to an embodiment of the present invention.

FIG. 2 is an enlarged view of a portion of the structure of FIG. 1.

FIG. 3 is a cut-away perspective view of a board structure according to another embodiment of the present invention.

FIG. 4 is an enlarged view of a portion of the structure of FIG. 3.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The following detailed description is of the best presently contemplated modes of carrying out the invention. This description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating general principles of embodiments of the invention. The scope of the invention is defined by the appended claims.

FIGS. 1 and 2 illustrate one embodiment of a lightweight man-made board that includes a face board 1, a base board 2, and a center layer 3 that are combined as a single unit. The center layer 3 is positioned between the face board 1 and the base board 2. A frame structure comprised of tubular sections 31 is provided on the four sides of the center layer 3 to encircle the center layer 3. The two surfaces of the frame structure are adhered to the face board 1 and the base board 2. An intermediate board 32 is arranged in the cavity enclosed by the tubular sections 31, the face board 1 and the base board 2, and is fixed in the cavity by support blocks 33 that are connected to the face board 1 and the base board 2. There is a space left between the intermediate board 32 and the face board 1 and the base board 2. A space is also left between the tubular sections 31 and the support blocks 33. All of these spaces are filled with a filler 34. Several installation grooves 4 used for hanging goods can be formed in the outer surface of the face board 1, as long as the intermediate board 32 in the center layer 3 has sufficient thickness and strength.

The tubular sections 31 may be hollow plastic tube sections. The intermediate board 32 may be made of a medium density fiberboard with sufficient strength. The filler 34 may be light foam. The support blocks 33 may be solid wood blocks.

In this embodiment, since hollow plastic tubes are used as tubular sections 31, the weight of the overall structure is reduced while sufficient strength is provided. In addition, the entire frame structure formed by the tubular sections 31 can prevent moisture from entering the center layer 3, and the entire board can be prevented from experiencing deformation caused by moisture. In order to reduce the weight while providing the overall board with sufficient strength, a stable box structure is formed inside center layer 3. This box structure is formed by the intermediate board 32 made of a medium density fiberboard, support blocks 33 fixed on the four sides of the intermediate board 32, and the base board 2. The box structure is integrated with the face board 1 through the support blocks 33. This provides the lightweight man-made board with sufficient bending strength. Therefore, even when installation grooves 4 are formed in the surface of the face board 1 and goods are hung on the board, the overall board will not experience bending deformation. Also, the light filler 34 that is filled in the hollow parts of the central layer prevents the face board 1 and the base board 2 from caving in due to local stress, without increasing the overall weight of the board.

FIGS. 3 and 4 illustrate modifications made to the lightweight man-made board in FIGS. 1 and 2. The difference between this embodiment and the embodiment in FIGS. 1 and 2 is that the installation grooves 4 are formed in the outer surface of both the face board 1 and the base board 2, and a reinforcing board 35 is added between the intermediate board 32 and the face board 1 inside the center layer 3. The reinforcing board 35 is fixed to the face board 1 and the base board 2 with the aid of the support blocks 33 fixed on its four sides. A filler 34 fills the space left between the reinforcing board 35 and the face board 1.

In the board of FIGS. 3 and 4, the intermediate board 32 and the reinforcing board 35 in the center layer 3 form two stable box structures with the support blocks 33 as well as the face board 1 and the base board 2. The two box structures are both integrated with the face board 1 and the base board 2. The overall strength of the board is further increased in this way. Also, the symmetrical nature of the board further guarantees the anti-deformation capability of the lightweight man-made board.

The boards according to embodiments of the present invention have the following features and benefits. The board has a three-layer structure that includes a face board 1, a center layer 3, and a base board 2. The surrounding sides of the intermediate board 32 are sealed with a frame structure. The three layers are therefore combined into a single unit, and the frame structure can thus prevent the entire board from experiencing warping deformation. Since the center layer 3 has many hollow parts that are filled with a light filler 34, the overall weight of the board is reduced. This solves the problem of excessive weight during transportation.

In addition, in order to provide the board with sufficient strength, an intermediate board 32 with certain strength is added inside the frame structure of the center layer 32. The support blocks 33 fixed on the enclosing sides of the intermediate board 32 enable the intermediate board 32 to form a stable box structure together with the base board 2. This gives the overall board sufficient bending strength. Thus, even if installation grooves are formed in the face board 1, the overall strength of the board will not be affected. When the frame structure is made of a hollow plastic material, moisture can be prevented from penetrating into the center layer 3. The entire board can thereby be prevented from experiencing deformation caused by moisture.

While the description above refers to particular embodiments of the present invention, it will be understood that many modifications may be made without departing from the spirit thereof. The accompanying claims are intended to cover such modifications as would fall within the true scope and spirit of the present invention.





 
Previous Patent: Disposable siding clip

Next Patent: Truss connector