Patent Publication Number: US-2013251964-A1

Title: Composite Board

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to a composite board; more particularly, the present invention relates to a composite board with a decorative effect, which is made of 3D fiberglass and resin. 
     2. Description of the Related Art 
     General construction and decoration boards such as planks and marble boards, or general transport boards such as metal sheets, all have great toughness and decorative effect. But those boards have disadvantages such as high expense, heavy weight, and difficulty of use in construction. Therefore, the composite board has been developed for construction and transport. For example, the composite board disclosed in U.S. Pat. No. 4,746,560 includes a reinforced base portion made of a glass mat of the prior art impregnated with a polyester resin for providing toughness. A polyester resin-impregnated graphic print sheet is located above the reinforced base portion for providing a decorative effect. There is a transparent polyester resin overlay located above the polyester resin-impregnated graphic print sheet for protecting the polyester resin-impregnated graphic print sheet, and for allowing the user to see the pattern of the polyester resin-impregnated graphic print sheet via the transparent polyester resin. However, the glass mat of the prior art is brittle, so the toughness of the composite board is insufficient. 
     Another example is the composite board disclosed in U.S. Pat. No. 4,983,442, which includes a core of fiberglass mattes impregnated with a thermoplastic resin. A strip of semi-rigid urethane foam surrounds the edges of the core. Both the core and the strip have great toughness. There are two reinforced layers located on both surfaces of the core. The reinforced layer is made of fiberglass, allowing the composite board to have improved toughness. A decorative layer is located on the top of the composite board, and a scrim layer is located on the bottom of the composite board, for providing a decorative effect. However, in industry, a strip with the size exactly covering the core is usually made by molding methods. If the manufacturer needs to produce different sizes of the strip for the core, the manufacturer must produce a casting mold of another size for the strip, such that the cost of the composite board will increase. 
     Therefore, there is a need to provide a light-weight composite board with a decorative function, great toughness, and low cost. 
     SUMMARY OF THE INVENTION 
     It is an object of the present invention to provide a composite board with landscaping and decorative functions. 
     To achieve the abovementioned object, a composite board is disclosed in the present invention. In the first embodiment of the present invention, the composite board includes a first decoration layer, a first interlayer, and a first protection layer. The first interlayer is located under the first decoration layer. The first interlayer is made of 3D fiberglass impregnated with a resin. The first decoration layer is located under the first protection layer. 
     In the second embodiment of the present invention, the composite board includes a foundation layer, a first interlayer, a first decoration layer, and a first protection layer. The foundation layer is made of foam or light fireproof material. The first interlayer is made of 3D fiberglass impregnated with a resin. The first interlayer is located above the foundation layer, the first decoration layer is located above the first interlayer, and the first protection layer is located above the first decoration layer. 
     In the third embodiment of the present invention, the composite board includes a foundation layer, a first interlayer, a first decoration layer, a first protection layer, a second interlayer, a second decoration layer, and a second protection layer. The foundation layer is made of foam light fireproof material. The first interlayer and the second interlayer are made of 3D fiberglass impregnated with a resin. The first interlayer is located above the foundation layer, the first decoration layer is located above the first interlayer, the first protection layer is located above the first decoration layer, the second interlayer is located under the foundation layer, the second decoration layer is located under the second interlayer, and the second protection layer is located under the second decoration layer. 
     In the fourth embodiment of the present invention, the composite board includes a foundation layer, a first interlayer, a first decoration layer, a first protection layer, and a metal sheet. The foundation layer is made of foam light fireproof material. The first interlayer and the second interlayer are made of 3D fiberglass impregnated with a resin. The metal sheet is located above the foundation layer. The first interlayer is located above the metal sheet. The first decoration layer is located above the first interlayer. The first protection layer is located above the first decoration layer. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  illustrates a schematic drawing of the composite board according to the first embodiment of the present invention. 
         FIG. 2  illustrates an exploded perspective view of the composite board according to the first embodiment of the present invention. 
         FIG. 3  illustrates a schematic drawing of the composite board according to the second embodiment of the present invention. 
         FIG. 4  illustrates an exploded perspective view of the composite board according to the second embodiment of the present invention. 
         FIG. 5  illustrates a schematic drawing of the composite board according to the third embodiment of the present invention. 
         FIG. 6  illustrates an exploded perspective view of the composite board according to the third embodiment of the present invention. 
         FIG. 7  illustrates a schematic drawing of the composite board according to the fourth embodiment of the present invention. 
         FIG. 8  illustrates an exploded perspective view of the composite board according to the fourth embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     These and other objects and advantages of the present invention will become apparent from the following description of the accompanying drawings, which discloses several embodiments of the present invention. It is to be understood that the drawings are to be used for purposes of illustration only, and not as a definition of the invention. 
     Please refer to  FIG. 1  and  FIG. 2  for the first embodiment of the present invention.  FIG. 1  illustrates a schematic drawing of the composite board according to the first embodiment of the present invention.  FIG. 2  illustrates an exploded perspective view of the composite board according to the first embodiment of the present invention. 
     As shown in  FIG. 1  and  FIG. 2 , in the first embodiment, the composite board  1  of the present invention comprises a first protection layer  50 , a first decoration layer  40 , and a first interlayer  30 . 
     In the first embodiment, the first decoration layer  40  is a woodprint paper (a printing paper) or a woodprint cloth (a printing cloth), used for providing the decorative effect for the composite board  1 . The first decoration layer  40  is located above the first interlayer  30 . The first protection layer  50  is made of transparent resin, is located above the first decoration layer  40 , and is used for protecting the first decoration layer  40 , allowing the user to see the color or pattern of the first decoration layer  40  via the transparent resin of the first protection layer  50 . The first interlayer  30  is used for enhancing the toughness of the composite board  1  and is pasted on the first decoration layer  40 . The first interlayer  30  is made of 3D fiberglass impregnated with an adhesive; in the present embodiment, the adhesive is a resin. When the 3D fiberglass of the first interlayer  30  absorbs the resin and solidifies, honeycomb structures will be formed in the 3D fiberglass, such that the toughness of the 3D fiberglass is better than the fiberglass of the prior art. However, the adhesive of the present invention is not limited to a resin. In the first embodiment, the thickness is about 0.3 cm-0.7 cm, such that the composite board  1  is suitable to replace a thin sheet, such as a tile. 
     Please refer to  FIG. 3  and  FIG. 4  for the second embodiment of the present invention.  FIG. 3  illustrates a schematic drawing of the composite board according to the second embodiment of the present invention.  FIG. 4  illustrates an exploded perspective view of the composite board according to the second embodiment of the present invention. 
     As shown in  FIG. 3  and  FIG. 4 , the difference between the second embodiment and the first embodiment is that the composite board  1   a  of the second embodiment further comprises a foundation layer  10  located under the first interlayer  30 . The foundation layer  10  is made of foam, such as polyurethane (PU), ethylene-vinyl acetate (EVA), expanded polystyrene (EPS), and polyethylene (PE), or light fireproof material, such as silicon dioxide, Aersio, and artificial pozzolana. The foundation layer  10  is used for enhancing the sound proofing or fireproof effect, and increasing the thickness of the composite board  1   a.  In the second embodiment, the foundation layer  10  accounts for the greatest part of the thickness of the composite board  1   a.  The composite board  1   a  of the second embodiment can be used as a single wall or a single-sided divider. Please refer to  FIG. 5  and  FIG. 6  for the third embodiment of the present invention.  FIG. 5  illustrates a schematic drawing of the composite board according to the third embodiment of the present invention.  FIG. 6  illustrates an exploded perspective view of the composite board according to the third embodiment of the present invention. As shown in  FIG. 5  and  FIG. 6 , the difference between the third embodiment and the second embodiment is that the composite board  1   b  further comprises a second interlayer  31 , a second decoration layer  41 , and a second protection layer  51 . 
     The second interlayer  31  is located under the foundation layer  10  and is made of 3D fiberglass impregnated with a resin. The second decoration layer  41  is a woodprint paper (a printing paper) or a woodprint cloth (a printing cloth), used for providing the decorative effect for the composite board  1   b.  The second decoration layer  41  is located under the second interlayer  31 . The second protection layer  51  is made of transparent resin, is located under the second decoration layer  41 , and is used for protecting the second decoration layer  41 , allowing the user to see the color or pattern of the second decoration layer  41  via the transparent resin of the second protection layer  51 . The composite board  1   b  of the third embodiment, which has a two-sided decorative effect, can be used as a partition wall. However, the design of the present invention is not limited to the abovementioned embodiments. For example, the first decoration layer  40  and the second decoration layer  41  are not limited to woodprint paper; they can be other kinds of paper, cloth, and plastic sheeting; the decorative appearance can be a stone, marble, or metal texture surface. The material of the first protection layer  50  and the second protection layer  51  are not limited to the transparent resin; they can be other materials which are transparent, are wear resistant, and can be coated on the surface of the first decoration layer  40  and the second decoration layer  41 . 
     Please refer to  FIG. 7  and  FIG. 8  for the fourth embodiment of the present invention.  FIG. 7  illustrates a schematic drawing of the composite board according to the fourth embodiment of the present invention.  FIG. 8  illustrates an exploded perspective view of the composite board according to the fourth embodiment of the present invention. 
     As shown in  FIG. 7  and  FIG. 8 , the difference between the fourth embodiment and the second embodiment is that the composite board  1   c  further comprises a metal sheet  60 . The metal sheet  60  is located between the foundation layer  10  and the first interlayer  30 . The metal sheet  60  is made of aluminum foil which has heat resistance or heat insulation effect, to prevent or delay the foam of the foundation layer  10  of the composite board  1   c  melts when the temperature is high. The composite board  1   c  of the fourth embodiment can be used as fireproof building materials. 
     It is noted that the above-mentioned embodiments are only for illustration. It is intended that the present invention cover modifications and variations of this invention provided they fall within the scope of the following claims and their equivalents. Therefore, it will be apparent to those skilled in the art that various modifications and variations can be made to the structure of the present invention without departing from the scope or spirit of the invention.