Abstract:
A method for producing a composite plastic sheet comprises: (1) producing an upper shell with a desired shape by vacuum processing a plastic sheet directly according to the design, a connection wall extends downwardly from the edge of this upper shell in a direction substantially vertical to the surface of the shell; (2) producing a lower shell with a desired shape by injecting a plastic sheet directly according to the design, a connection wall extends upwardly from the edge of this lower shell in a direction substantially vertical to the surface of the shell. The lower surface of the shell is smooth, while the upper surface of the shell has many reinforcing ribs integrally manufactured, and the top surface, which is composed of these ribs, is coincided with the lower surface of the upper shell; and (3) connecting the lower face of the upper shell and the top surface of the lower shell by a binder or ultrasonic welding; at the same time, connecting the connection walls of the upper shell and the lower shell by a binder, ultrasonic welding, a buckle, or a screw thread. The composite plastic sheet includes an upper shell with a desired shape made by vacuum processing a plastic sheet directly according to the design, a connection wall extends downwardly from the edge of this upper shell in a direction substantially vertical to the surface of the shell; and a lower shell with a desired shape made by injecting a plastic sheet directly according to the design, a connection wall extends upwardly from the edge of this lower shell in a direction substantially vertical to the surface of the shell. And the lower surface of the shell is smooth, while the upper surface of the shell has many reinforcing ribs integrally manufactured. The top surface, which is composed of these ribs, is coincided with the lower surface of the upper shell. And the connection walls of the upper shell and the lower shell are jointed together to make a closed composite sheet. The top surface is under the lower surface of the upper shell, and within the composite sheet. The seat back of a chair includes the above composite plastic sheet.

Description:
TECHNICAL FIELD 
       [0001]    The present invention relates to a plastic composite board and its manufacturing method. 
       BACKGROUND OF ARTS 
       [0002]    Due to the lack of the wood materials and the improvement of the capability of plastic board, the plastic board is used more and more widely. The Chinese patent application number 96120421.4 discloses a plastic hollow plate for postal packing chest and its production technology; the plastic hollow plate is made up of polyethylen or polypropylene and pigment through extruding-out, and has an internal hollow structure with vertical reinforcing ribs at intervals, and has equidistant vertical reinforcement pieces in the vertical direction with the plane. Its advantages include no poison and odour, high strength and shock and corrosion resistances, light, weight, and long service life. But the plastic hollow plate is only fit to plane plate, such as box body; the plastic hollow plate can not be used as special shape, such as backrest of chair or seat board and so on. 
         [0003]    It has another board of blow molding or board of vacuum forming technology, which also can be made as hollow board with some reinforcement pieces on its lower faceplate for improving its bearing power; the lower faceplate of the board is scraggy, so the board can not be used as double sided board, such as backrest of chair. 
       DESCRIPTION 
       [0004]    The purpose of the present invention is to overcome the disadvantages of the known technology, and to supply a plastic composite board and its manufacturing method; the plastic composite board can be made to board of curved surface with any shape, and has a light weight, a high strength, low manufacturing cost, and can be used as double sided board. 
         [0005]    The manufacturing method of the plastic composite board of the present invention adopts technique proposal as follows: the manufacturing method of a plastic composite board, comprising 
         [0006]    A, plastic board of required shape is directly made by vacuum forming technology as the upper cover board, whose edge extends downwards to form a suberect connective wall; 
         [0007]    B, plastic board of required shape is directly made by injection moulding as the nether soleplate with some reinforcement pieces; the undersurface of the nether soleplate is glaze; the upper surface of the nether soleplate is molded with some integrative reinforcement pieces; the top surface constituted by some reinforcement pieces is matched with the bottom surface of the upper cover board; the edge of the nether soleplate extends upwards to form a suberect connective wall; 
         [0008]    C, the top surface of reinforcement pieces is fixed to the bottom surface of the upper cover board by gluewater or ultrasonic jointing; at the same time, the connective wall of the upper cover board is fixed to the connective wall of the nether soleplate by gluewater or welding or buckling joint or screw thread. 
         [0009]    A plastic composite board of the present invention, comprises a composite upper cover board and a composite nether soleplate; the upper cover board is board of curved surface or surface board, which is made by direct vacuum forming technology according to the desired shape of the plastic composite board; the edge of the upper cover board extends downwards to form a suberect connective wall; 
         [0010]    The nether soleplate is directly made by injection moulding according to the desired shape of the plastic composite board. The undersurface of the nether soleplate is glaze; the upper surface of the nether soleplate is molded with some reinforcement pieces. The top surface constituted by reinforcement pieces is matched with the bottom surface of the upper cover board. The edge of the nether soleplate extends upwards to form a suberect connective wall. 
         [0011]    The connective wall of the upper cover board is fixed to the connective wall of the nether soleplate to form a closed composite board; the top surface of every reinforcement pieces is located under the bottom surface of the upper cover board and every reinforcement pieces are located inside of the composite board. 
         [0012]    The undersurface of said nether soleplate is plane or curved surface. 
         [0013]    Said upper cover board buckles on the nether soleplate; the connective wall of the upper cover board is fixed to the connective wall of the nether soleplate by gluewater, welding, buckling joint or screw thread. 
         [0014]    The upper surface of said every reinforcement pieces is fixed to the bottom surface of the upper cover board by gluewater or ultrasonic jointing. 
         [0015]    The upper surface of said upper cover board is composite with film layer; the film layer is design of grain of wood or marble or other natural objects. 
         [0016]    The bottom of the outside of the connective wall of said nether soleplate has an orientation protruding part; the width of the protruding part is equal to the thickness of the connective wall of the upper cover board. 
         [0017]    The bottom of the outside of the connective wall of said nether soleplate extends outside to form an orientation slot; the width of the orientation slot is equal to the thickness of the connective wall of the upper cover board. 
         [0018]    There are some holes on the superposition side of the upper cover board and the nether soleplate, and matched with some selftapping screws; the upper cover board is fixed to the nether soleplate by selftapping screws locked into the holes. 
         [0019]    There are some holes or grooves on the superposition side of the upper cover board and the nether soleplate, and matched with some elasticity hooks with sidesteps; the upper cover board is fixed to the nether soleplate by inserting the elasticity hooks into the holes or grooves through outside force. 
         [0020]    Said upper cover board is fixed to the nether soleplate by bolt and matched threaded hole, or by bolt and matched inner nut. 
         [0021]    According to the description of the manufacturing method of the plastic composite board of the present invention, comparing with the background arts, the present invention has virtues as follows: 
         [0022]    The manufacturing method of the plastic composite board of the present invention, plastic board of required shape is directly made by vacuum forming technology as the upper cover board; plastic board of required shape is directly made by injection moulding as the nether soleplate with some reinforcement pieces, the top surface constituted by some reinforcement pieces is matched with the bottom surface of the upper cover board; as the upper cover board and the nether soleplate of the present invention separately adopts vacuum forming technology and injection moulding, which to make the plastic composite board have the virtue of light weight of board of vacuum forming technology, and have the virtue of high strength of board of injection moulding; and that, the upper surface of the upper cover board can be composite with film layer, the undersurface of the nether soleplate can be slick plane or slick curved surface; so the plastic composite board can directly replace curved wood board or solid wood board (such as replacing curved wood board and solid wood board as the backrest and seat board of chair), and it has lighter weigh than the curved wood board or solid wood board, has a higher strength than the curved wood board or the solid wood board, has a more beautiful appearance than the curved wood board or the solid wood board. 
         [0023]    According to the description of the plastic composite board of the present invention, comparing with the background arts, the present invention has virtues as follows: 
         [0024]    Firstly, the upper cover board of the plastic composite board of the present invention is made by direct vacuum forming technology according to desired shape of the upper surface of the plastic composite board, which is machininged easily, has a high precision of machining, has a light weight and a high strength and a low manufacturing cost; the nether soleplate is made by direct injection moulding according to the desired shape of the plastic composite board, which is machininged easily, has a high precision of machining, has a high strength and a low manufacturing cost. 
         [0025]    Secondly, the top surface constituted by reinforcement pieces is matched with the bottom surface of the upper cover board, and the undersurface of the upper cover board leans against the upper surface of every reinforcement pieces, and every reinforcement pieces support the upper cover board; every reinforcement pieces increase the strength of the undersurface, and increase the strength of the nether soleplate, and increase the strength of the plastic composite board. 
         [0026]    Thirdly, the upper cover board buckles on the undersurface of the nether soleplate; the upper cover board is fixed to the nether soleplate by gluewater, welding, buckling joint or screw thread, which has a convenient connection and has a high connection intensity. 
         [0027]    Fourthly, the upper surface of every reinforcement pieces is fixed to the bottom surface of the upper cover board by gluewater or ultrasonic jointing, which has a high connection intensity and is machininged expediently, and increase the matched intensity of the upper cover board and the nether soleplate, and increase the intensity of the whole plastic composite board. 
         [0028]    Fifthly, there are some holes on the superposition side of the upper cover board and the nether soleplate, and matched with some selftapping screws; the upper cover board is fixed to the nether soleplate by selftapping screws locked into the holes, which has a convenient connection and has a low manufacturing cost. 
         [0029]    Sixthly, the upper cover board is fixed to the nether soleplate by inserting the elasticity hooks into the holes or grooves through outside force, which has a convenient connection and a high connection intensity and is knock-down. 
         [0030]    Seventhly, the upper cover board is fixed to the nether soleplate by bolt and matched threaded hole, or by bolt and matched inner nut, which has high connection intensity and is knock-down. 
     
    
     
       BRIEF DESCRIPTION OF ATTACHED DRAWINGS 
         [0031]      FIG. 1  is the cutaway view of the plastic composite board adopting the first connection mode of the present invention. 
           [0032]      FIG. 2  is the disassembled cutaway view of the plastic composite board adopting the first connection mode of the present invention in  FIG. 1 . 
           [0033]      FIG. 3  is the cutaway view of the plastic composite board adopting the second connection mode of the present invention. 
           [0034]      FIG. 4  is the disassembled cutaway view of the plastic composite board adopting the second connection mode of the present invention in  FIG. 3 . 
           [0035]      FIG. 5  is the cutaway view of the plastic composite board adopting the third connection mode of the present invention. 
           [0036]      FIG. 6  is the disassembled cutaway view of the plastic composite board adopting the third connection mode of the present invention in  FIG. 5 . 
           [0037]      FIG. 7  is the cutaway view of the plastic composite board adopting the fourth connection mode of the present invention. 
           [0038]      FIG. 8  is the disassembled cutaway view of the plastic composite board adopting the fourth connection mode of the present invention in  FIG. 7 . 
           [0039]      FIG. 9  is the cutaway view of the plastic composite board adopting the fifth connection mode of the present invention. 
           [0040]      FIG. 10  is the disassembled cutaway view of the plastic composite board adopting the fifth connection mode of the present invention in  FIG. 9 . 
           [0041]      FIG. 11  is the cutaway view of the plastic composite board adopting the sixth connection mode of the present invention. 
           [0042]      FIG. 12  is the disassembled cutaway view of the plastic composite board adopting the sixth connection mode of the present invention in  FIG. 11 . 
           [0043]      FIG. 13  is the cutaway view of the plastic composite board adopting the seventh connection mode of the present invention. 
           [0044]      FIG. 14  is the disassembled cutaway view of the plastic composite board adopting the seventh connection mode of the present invention in  FIG. 13 . 
           [0045]      FIG. 15  is the cutaway view of the plastic composite board adopting the eighth connection mode of the present invention. 
           [0046]      FIG. 16  is the disassembled cutaway view of the plastic composite board adopting the eighth connection mode of the present invention in  FIG. 15 . 
           [0047]      FIG. 17  is the cutaway view of the upper cover board printed with printing layer. 
           [0048]      FIG. 18  is the three-dimensional sketch map of the chair in embodiment 1. 
           [0049]      FIG. 19  is cutaway view of the chair in embodiment 1. 
           [0050]      FIG. 20  is cutaway view of the chair in embodiment 2. 
       
    
    
     EMBODIMENTS 
       [0051]    Referring to attached drawings, we will explain the present invention as follows. 
         [0052]    Manufacturing method of a plastic composite board, as shown in  FIGS. 1 and 2 , having steps as follows: 
         [0053]    A, plastic board of required shape is directly made by vacuum forming technology as the upper cover board  10 , whose edge extends downwards to form a suberect connective wall  11 ; 
         [0054]    B, plastic board of required shape is directly made by injection moulding as the nether soleplate  12  with some reinforcement pieces  16 ; the undersurface  14  of the nether soleplate  12  is glaze; the upper surface of the nether soleplate  12  is molded with some integrative reinforcement pieces  16 ; the top surface constituted by some reinforcement pieces  16  is matched with the bottom surface of the upper cover board  10 ; the edge of the nether soleplate  12  extends upwards to form a suberect connective wall  13 ; 
         [0055]    C, the top surface of reinforcement pieces  16  is fixed to the bottom surface of the upper cover board  10  by gluewater or ultrasonic jointing; at the same time, the connective wall  11  of the upper cover board  10  is fixed to the connective wall  13  of the nether soleplate  12  by gluewater or welding or buckling joint or screw thread. 
         [0056]    A plastic composite board, as shown in  FIG. 2 , comprising the composite upper cover board  10  and the composite nether soleplate  12 . The upper cover board  10  is board of curved surface or surface board, which is made by direct vacuum forming technology according to the desired shape of the plastic composite board; the nether soleplate  12  is directly made by injection moulding according to the desired shape of the plastic composite board. The undersurface  14  of the nether soleplate  12  is glaze; the upper surface of the nether soleplate  12  is molded with some integrative reinforcement pieces  16 . The top surface constituted by reinforcement pieces  16  is matched with the bottom surface of the upper cover board  10 . The top surface of every reinforcement pieces  16  is located under the bottom surface of the upper cover board  10 ; every reinforcement pieces  16  are located between the upper cover board  10  and the nether soleplate  12 , namely the upper cover board  10  is fixed to the nether soleplate  12  to form a close composite board. 
         [0057]    Some reinforcement pieces  16  are located on the upper surface of the nether soleplate  12  regularly; the number of reinforcement pieces  16  is designed by the area and the height of the plastic composite board and the intensity demand of the design. 
         [0058]    As shown in  FIG. 17 , both the upper surface of the upper cover board  10  and the undersurface  14  of the soleplate  12  are printed with printing layer  18 ; the printing layer  18  is design of grain of wood or marble or other natural objects. The upper cover board  10  is single-layer plastic board or multi-layer plastic board made by vacuum forming technology; the height of the plastic board varied from 0.3 to 4 mm. The plastic composite board has a beautiful appearance and a thin thickness. The materials of the upper cover board  10  are all PP, PE, ABS or other engineering plastics. 
         [0059]    The upper cover board  10  of the present invention is fixed to the nether soleplate  12  by modes as follows: 
         [0060]    1, buckling and bonding with gluewater: as shown in  FIGS. 1 and 2 , the bottom of the outside of the connective wall  13  of the nether soleplate  12  has an orientation protruding part  15 ; the width of the protruding part  15  is equal to the thickness of the connective wall  11  of the upper cover board  10 . The upper cover board  10  buckles on the nether soleplate  12 ; the nether head face of the connective wall  11  of the upper cover board  10  leans against the protruding part  15 ; the connective wall  11  of the upper cover board  10  is fixed to the connective wall  13  of the nether soleplate  11  by gluewater. 
         [0061]    2, buckling and hook connection: as shown in  FIGS. 3 and 4 , the bottom of the outside of the connective wall  13  of the nether soleplate  12  has an orientation protruding part  15 ; the width of the protruding part  15  is equal to the thickness of the connective wall  11  of the upper cover board  10 . There is orientation hole on the superposition side of the connective wall  11  of the upper cover board  10  fixed to the connective wall  13  of the nether soleplate  11 , and there are some elasticity hooks  22  with sidestep. The upper cover board  10  buckles on the nether soleplate  12 ; the nether head face of the connective wall  11  of the upper cover board  10  leans against the protruding part  15 ; the elasticity hook  22  is inserted into the orientation protruding part to fix by outside force. 
         [0062]    3, buckling and screw connection: as shown in  FIGS. 5 and 6 , has difference with buckling and hook connection: the upper cover board  10  buckles on the nether soleplate  12 ; the nether head face of the connective wall  11  of the upper cover board  10  leans against the protruding part  15 ; it is fixed by selftapping screw  20  locked into the orientation hole. 
         [0063]    4, buckling and clamping connection: as shown in  FIGS. 7 and 8 , the bottom of the outside of the connective wall  13  of the nether soleplate  12  has an orientation protruding part  15 ; the width of the protruding part  15  is equal to the thickness of the connective wall  11  of the upper cover board  10 . There is clamping hole  34  on the connective wall  11  of the upper cover board  10 ; accordingly there is clamping piece  36  on the connective wall  13  of the nether soleplate  12 . The clamping piece  36  is taper with a smaller upside and a bigger downside; the upper cover board  10  is fixed to the nether soleplate  12  by clamp connection of the clamping piece  34  and the clamping hole  36 . 
         [0064]    5, plug and bonding with gluewater: as shown in  FIGS. 9 and 10 , the bottom of the outside of the connective wall  13  of the nether soleplate  12  extends outside to form an orientation slot  38 . The width of the orientation slot  38  is equal to the thickness of the connective wall  11  of the upper cover board  10 . The nether head face of the connective wall  11  of the upper cover board  10  plugs into the orientation slot  38 ; the connective wall  11  of the upper cover board  10  is fixed to the connective wall  13  of the nether soleplate  12  by gluewater. 
         [0065]      6 , plug and hook connection: as shown in  FIGS. 11 and 12 , the bottom of the outside of the connective wall  13  of the nether soleplate  12  extends outside to form an orientation slot  38 . The width of the orientation slot  38  is equal to the thickness of the connective wall  11  of the upper cover board  10 . There is orientation hole on the superposition side of the connective wall  11  of the upper cover board  10  fixed to the connective wall  13  of the nether soleplate  11 , and there are some elasticity hooks  22  with sidestep. The nether head face of the connective wall  11  of the upper cover board  10  plugs into the orientation slot  38 ; the elasticity hook  22  is inserted into the orientation protruding part to fix by outside force, to make the upper cover board  10  having knock-down connection with the nether soleplate  12 . 
         [0066]    7, plug and screw connection: as shown in  FIGS. 13 and 14 , has difference with the buckling and hook connection: the nether head face of the connective wall  11  of the upper cover board  10  plugs into the orientation slot  38 , and the connective wall  11  of the upper cover board  10  is locked by selftapping screw  20 , to make the upper cover board  10  having knock-down connection with the nether soleplate  12 . 
         [0067]    8, plug and clamping connection: as shown in  FIGS. 15 and 16 , the bottom of the outside of the connective wall  13  of the nether soleplate  12  extends outside to form an orientation slot  38 . The width of the orientation slot  38  is equal to the thickness of the connective wall  11  of the upper cover board  10 . There is clamping hole  34  on the connective wall  11  of the upper cover board  10 , accordingly there is clamping piece  36  on the connective wall  13  of the nether soleplate  12 . The clamping piece  36  is taper with a smaller upside and a bigger downside; the upper cover board  10  is fixed to the nether soleplate  12  by clamp connection of the clamping piece  34  and the clamping hole  36 . 
         [0068]    The top surface of reinforcement pieces  16  is fixed to the bottom surface of the upper cover board  10  by gluewater or ultrasonic jointing. The upper surface constituted of every reinforcement pieces  16  fits into the bottom surface of the upper cover board; the upper cover board  10  is fixed to the nether soleplate  12  to form a close composite board; every reinforcement pieces  16  locate in the composite board. The top surfaces of every reinforcement pieces  16  fits into the corresponding parts of the bottom surface of the upper cover board  10 . 
         [0069]    We will describe the present invention with embodiments as follows. 
         [0070]    Embodiment 1, a swivel chair, as shown in  FIGS. 18 and 19 , comprising a base  24 , a leg brace  26 , a seat board  28 , a backrest  30  and a connective pole  32 . 
         [0071]    The base  24  comprises a pedestal and five feet bars which is fixed to the pedestal equably; feet bars have universal idler wheels, so the base  24  can move. 
         [0072]    The leg brace  26  is fixed to the center of the pedestal; the leg brace  26  comprises a sleeve, a touring bar which has bell and spigot joint with the sleeve, a lifter set locating between the sleeve and the touring bar, a governor lever for accommodating the lifter set. It can accommodate the height of the leg brace  26  by accommodating the lift and fall of the touring bar. 
         [0073]    Early seat board  28  and backrest  30  are made by curved wood board or solid wood board, which has a big weight and wastes wood materials. The seat board  28  and the backrest  30  of the present invention adopt the above plastic composite board, which has a light weight, a good strength, an appropriate curved surface of outer surface, and can be printed with grain of wood or marbling according to the require of people. 
         [0074]    The seat board  28  is board of curved surface with convex upper part, comprises the upper cover board  10  of curved surface with convex upper part made by vacuum forming technology; the circumambience of the upper cover board  10  extends downwards to form a suberect connective wall  11 ; a nether soleplate  12  made by injection moulding. The undersurface  14  of the nether soleplate  12  is glaze; the upper surface of the nether soleplate  12  is molded with some integrative reinforcement pieces  16 . The top surface constituted by reinforcement pieces  16  is matched with the bottom surface of the upper cover board  10 . The circumambience of the nether soleplate  12  extends upwards to form a suberect connective wall  13 . The upper cover board  10  buckles on the nether soleplate  12 ; every reinforcement pieces  16  are locate between the upper cover board  10  and the nether soleplate  12 . The top surface of reinforcement pieces  16  is fixed to the bottom surface of the upper cover board  10  by gluewater. The connective wall  11  of the upper cover board  10  is fixed to the connective wall  13  of the nether soleplate  12  by gluewater to form a closed composite board, namely the seat board  28 . 
         [0075]    The undersurface of the seat board  28  has a first connective part; the seat board  28  is fixed to the leg brace  26  by the first connective part; the undersurface of the nether soleplate  12  of the seat board  28  is molded with integrative installing surface for the first connective part. 
         [0076]    The backrest  30  has same structure with the seat board  28 ; the backrest  30  is composite board of curved surface with concave inner part; the back surface of the backrest has a second connective part fixedly. 
         [0077]    The connective  32  is L-shaped; one end of the connective  32  is fixed to the first connective part; the other end of the connective  32  is fixed to the second connective part. 
         [0078]    Embodiment 2, a plastic composite chair, as shown in  FIG. 20 , comprises a base  24 , a leg brace  26 , a seat board  28  and a backrest  30 . 
         [0079]    The base  24  comprises a pedestal and five feet bars which is fixed to the pedestal equably; feet bars have universal idler wheels, so the base  24  can move. 
         [0080]    The leg brace  26  is fixed to the center of the pedestal; the leg brace  26  comprises a sleeve, a touring bar which has bell and spigot joint with the sleeve, a lifter set locating between the sleeve and the touring bar, a governor lever for accommodating the lifter set. It can accommodate the height of the leg brace  26  by accommodating the lift and fall of the touring bar. 
         [0081]    The seat board  28  and the backrest  30  are L-shaped integrative plastic composite board; the upper cover board  10  of the seat board  28  and the backrest  30  is L-shaped board of vacuum forming technology; the nether soleplate  12  is board of injection molding having matched shape with the upper cover board  10 . The upper surface of the nether soleplate  12  is molded with some integrative reinforcement pieces  16  equably. The top surface constituted of the reinforcement pieces  16  has same shape with the undersurface of the upper cover board  10 . The edge of the upper cover board  10  extends downwards to form a connective wall  11 ; the edge of the nether soleplate  12  extends upwards to form a connective wall  13 . The upper cover board  10  buckles on the nether soleplate  12 . Every reinforcement pieces  16  are locate between the upper cover board  10  and the nether soleplate  12 . The top surface of reinforcement pieces  16  is fixed to the bottom surface of the upper cover board  10  by gluewater. The connective wall  11  of the upper cover board  10  is fixed to the connective wall  13  of the nether soleplate  12  by gluewater to form a closed composite board, namely the seat board  28 . 
         [0082]    While the present invention has been described in connection with what is considered the most practical and preferred embodiment, it is understood that present invention is not limited to the disclosed embodiment but is intended to cover various arrangements included within the spirit and scope of the broadest interpretation so as to encompass all such modifications and equivalent arrangements. 
       INDUSTRY PRACTICABILITY 
       [0083]    The plastic composite board of the present invention is constituted of an upper cover board made by vacuum forming technology and a nether soleplate made by injection molding with some reinforcement pieces, can be industrialized, has a good industry practicability.