WO2011107983A2

WO2011107983A2 - Light foamed elastic edged panel

Info

Publication number: WO2011107983A2
Application number: PCT/IL2011/000202
Authority: WO
Inventors: Amir Lavi; Jonathan Indyk
Original assignee: Amir Lavi; Jonathan Indyk
Priority date: 2010-03-01
Filing date: 2011-03-01
Publication date: 2011-09-09
Also published as: WO2011107983A3

Abstract

A new light foamed structure is provided. The structure comprises a top layer, a middle layer, a bottom layer, and glue, wherein the middle layer comprises essentially elastic material and the top and bottom layers comprise essentially un-strethable meterial. The glue is strongly adherent to the top and bottom layers to the middle layer, wherein the strength of the adherence being a result of at least the pressing of the top layer and the bottom layer toward each another, to a roughly 1 -40% distance of the top layer from the bottom layer compared to the distance before the pressing. After pressing, the distance regains its distance before pressing occured.

Description

LIGHT FOAMED ELASTIC EDGED PANEL

FIELD OF THE INVENTION The present invention relates to light and strong multilayered materials that may be used for example for shelving, casing, interior design, exhibitions, and displays and as furniture.

BACKGROUND OF THE INVENTION

Structures used for display and exhibitions, such as counter tops and shelves, are commonly made of panels made of MDF, plastic extruded material, or aluminum in combination with a solid foam, and paper/cardboard type sandwich structures with solid and un-elastic foam inside .

The MDF elements are heavy and the top and bottom surface and surrounding edges require extensive finishing covering or painting the MDF basic material that is unsightly, and the elements are cumbersome to use. Moreover, the MDF is fragile and is destroyed by moisture.

The aluminum/foam elements are lighter than the MDF ones, but are harder to cut and work with, can get dented, and as metal aluminum sheets for the top and bottom, they have limited usefulness, for example they don't have plastic transparent material on the surface to present embedded products therein.

Sandwiched structures such as a honeycomb or corrugated layer in between two layers of stiff material are typically relatively light and strong; see for example:

http://www.alibaba.com/productgs/278157238/Honeycomb_sandwich_panels _honeycomb_panel_ISO.html, yet the machining of the stiff material is difficult and exposed edges of the structures are unsightly and uneven, and require extensive finishing or covering. In addition, the paper/cardboard type of structures with solid/un-elastic material inside, is also vulnerable to water, and can easily get damaged as they have not any elasticity.

Also, materials in usage like PVC panels, which may not need extensive finishing on the edges, are however structures made from one material through-out, without combination of at least 2 types of stretchable and un- stretchable materials together; the absence of a composite structure entails making the product heavy in order to give it the sufficient strength.

There is a need for a light foamed structure that will be light and solid, with little or no need for additional treatment or painting to the edges after cutting or machining it, whether cut in either straight lines or curved shapes, and that is suitable for many different applications

In particular, there is a need for strong and solid structures with flexible and stretchable homogenous material in the middle, and a more inflexible, non-stretchable material on the outside layers, using glue for example, which "welds" the two types of materials together as one unit.

There is also a need for an elastic solid structure that when dropped by accident is insensitive to impact and therefore less vulnerable to cracking, breaking or scratching, in particular on the edges.

There is also a need for structures that are water resistant, and optionally floatable.

There is also a need for structures capable of receiving screws, and of allowing direct insertion of screws into them.

Also, in some applications it would be advantageous for the material to have magnetic qualities, so as to attach elements to it with the use of magnetic sheets

SUMMARY OF THE INVENTION

According to one aspect, a light foamed structure is provided, comprising: a top layer, a middle layer, a bottom layer and glue, wherein the middle layer is an essentially elastic material such as polyethylene or EPDM foam and the top and bottom layer are essentiallyunstrechable meterial for example polypropylene, formaica, aluminium, wood, perspex, PVC ABS, paper, cardboard or combinations thereof wherein the glue is strongly adherent to the top and bottom layers to the middle layer, the strength of the adherence being a result of at least the pressing of the top layer and the bottom layer toward each other, to a roughly 1 -40% distance of the top layer from the bottom layer compared to said distance before the pressing. The panel is capable of regaining its original volume after the pressing in the compression range stated above.

In preferred embodiments, the the foam is cross-linked.

The foam preferably comprises pores that are mostly not interconnected, such that each pore is essentially completely encased in polymeric elastic material.

The foam may have one or more of the charactersitics:

A density of 25-250 kg/m3; a dimensional stability of less than 2% change over 24 hours at 70°C for a 10mm thick specimen; temperature resistance of at least the range -60° to 90°C; and amenability to thermoforming, vacuum forming; CNC milling, lamination, die-cutting, splitting, butt welding, and combination with other foams, films, polymers and textiles by lamination or adhesion.

Best results are obtained with the structures having a thickness of at least 8mm.

The top layer and the bottom layer each preferably have a thickness of at least 0.5 mm.

The structure is typically waterproof. Some embodiments are floatable. In some embodiments, the structure allows insertion of screws or bolts or nails without prior drilling or forming a hole in the structure.

The layer edges of the panel are each typically essentially homogeneous and smooth, even after cutting the structure. The top and bottom layer are typically less stretchable, less flexible and/or more rigid than the middle layer.

When the top and/or bottom layer are ABS, the glue is preferably contact glue.

Preferably, the pressing of the top layer and the bottom layer toward each other, is to a 1 -40% distance, more preferably 5-25% distance, of the top layer form the bottom layer compared to said distance before the pressing.

BRIEF DESCRIPTION OF THE FIGURES

The following Figures are provided merely in order to better understand the present invention and appreciate its practical applications. Like components are denoted by like reference numerals.

Figure 1 a depicts a side view of a section of sandwich structure with screws directly screwed to the panel.

Figure 1 b shows an embodiment with a screw inserted into a dubel.

Figure 2 illustrates a light foamed structure with a embedded products in accordance with a preferred embodiment of the present invention.

Figure 3a shows a light foamed structure adhered to and between two less elastic layers, before firm adherence of the layers is performed.

Figure 3b illustrates the light foamed structure shown in figure 3a, after pressing of the layers together. Figure 4 illustrates the edges of the light foamed structure in accordance with a preferred embodiment of the present invention. Figure 5 illustrates connection between the edges of light foamed structures in accordance with a preferred embodiment of the present invention. Figure 6 shows a light foamed structure adapted to be strengthened by a strip of strong material embedded therein;

Figure 7a shows a light foamed structure composed of a foamed layer sandwiched between two layers of un-stretchable material;

Figure 7b shows a light foamed structure, composed of a foamed layer sandwiched between two layers of un-stretchable material, and further composed of a stretchable layer adhered to and covering an un-stretchable layer;

Figure 7c shows a light foamed structure, composed of a foamed layer sandwiched between two layers of un-stretchable material, and further composed of stretchable layers adhered to and covering the un-stretchable layers;

Figure 8a illustrates a light foamed structure such as shown in Figure 7a, in which the sizes of the un-stretchable layers are different from each other;

Figure 8b illustrates a structure similar to the one shown in Figure 7a, in folded and rectangular form;

Figure 8c illustrates a structure similar to the one shown in Figure 7a, in folded and triangular form; Figure 9a shows a structure similar to the one shown in Figure 8b, folded and adapted into a casing; Figure 9b shows an expanded view of a part of the structure illustrated in Figure 9a;

Figure 10 illustrates a 3-D character for display, composed of a light foamed structure;

Figure 1 1 shows insertion of an object such as an aluminum pipe into a panel; Figure 12 shows the resilience of a panel hit with a hammer, - Figure 13 shows furniture made with panels.

Figure 14 shows a structure including shelf panels held by supporting panels.

DETAILED DESCRIPTION OF THE INVENTION AND THE FIGURES

The present invention provides a unique light foamed structure that can be used for example for shelving, casing, interior design, exhibitions, and displays as an exhibition structure, display apparatus and as furniture.

The light foamed panel is made of a composite material. The materials used are polymeric wherein a fairly inelastic, unstrechable and/or rigid plastic is combined with a more, elastic, stretchable and/or less rigid material respectively, so as to establish a synergic panel that may have improved properties relative to the materials from which it is made, such as stiffness, tensile and/or yield strength. The layers remain separate and distinct on a macroscopic level within the finished structure, except perhaps at the interface between the layers. In some preferred embodiments, the panels comprise at least three layers, that comprise a top and a bottom layer that are relatively unstrechable/inflexible/rigid, and a middle layer which is more stretchable/flexible/less rigid. The middle layer is preferably polyethylene or EPDM foam; in more preferred embodiments, the polyethylene or EPDM is crosslinked.

In some preferred embodiments, the foam comprises pores that mostly not interconnected, such that each pore is essentially completely encased in polymeric elastic material. Such foam may be very light and spogy, yet waterproof. The pore size and crosslinking may widely vary, thereby a wide range of foam densities may be selected from, typically 25-250 kg/m³. Other preferable characteristics are: dimensional stability over 24 hours at 70°C - less than 2% change of a 10mm thick specimen; temperature resistance of at least the range -60° to 90°C; and amenable to thermoforming, vacuum forming; CNC milling, lamination, die-cutting, splitting, butt welding, and combination with other foams, films, polymers and textiles by lamination or adhesion.

Such polymers are commercially available, for example from Palziv, Israel.

The polymers of the middle layer may additionally have one or more of the following characteristics: a tensile strength (ISO 1798) ranging for example between roughly 250 and 2500, have an elongation (ISO 1798) roughly 150-200%, compression 10% (ISO 844) at between roughly 30-750 kPa, compression 25% (ISO 844) 50-850 kPa, compression 50% (ISO 844) 100-1250 kPa, and have shore oo hardness (ASTM D2240) roughly 40-95 oo.

A skilled in the art will recognize that the type of foamed polymer selected will depend upon the desired type of structure, for example its shape, intended use etc.

It will also be recognized that the optimal type of glue for best adherence between the top and bottom layers and the middle layer may vary according to the specific material selected, both the middle layer and the top and bottom layers, as well as the intended use of the panel, for example whether the panel will be subjected to extreme temperatures or submerged in certain liquids for extended periods of time, etc.

The edges of the sandwich structure are typically relatively smooth and consistently dense; Screws 40a, 40b can be easily and directly screwed to the panel with no difficulty and no need for preliminary drilling, as shown in the embodiments 100a, 100b respectively in Figs. 1 a and 1 b. The embodiment in Fig.1 a shows a screw 40a inserted directly into the panel 100a, and Fig.1 b shows a screw 40b inserted into a dubel 42, which is itself inserted into the panel 100b.

The panel may be composed only from plastic materials, and allows showcasing products or producing light effects from behind the structures when using transparent surfaces.

In other embodiments, the top and the bottom layer comprise one or more other materials, such as aluminum and/or wood. In some embodiments the top and/or bottom layer comprise material that may be printed upon; in some embodiments the top and/or bottom layer are printed.

Preferably, the foamed panel thickness is not less than 8 mm.

Reference is now made to Figures 2a-c illustrating a light foamed panel 200 with embedded products 50 in accordance with a preferred embodiment of the present invention. Apparatus 200 is a thermally insulated medical hamper and the products 50 are test tubes. The interior foamed material can be CNC machined to create an interior 202 in which products 50 are embedded. In some other embodiments, the products and panel may be designed so that the product looks like an integral part of the panel. An interior like 202 can be used for showcasing effects, or spotlighting from behind the panel.

Figure 3a shows how preferred panel embodiments may be manufactured. A light foamed structure 300 composed of a homogenous foamed relatively elastic layer 310 is adhered to and between two less elastic layers, top layer 320a, and bottom layer 320b, before firm adherence of the layers is performed. Glue (not shown) lightly adheres the two layers 320a, 320b to the middle layer 310. Two press plates 30a, 30b of a press are shown; the structure 300 is not pressed yet.

Figure 3b illustrates the light foamed structure 300 shown in figure 3a, after pressing of the layers together.

Preferably, the press is applied until the panel is compressed to between

1 and 40% of its original thickness. More preferably, the panel is compressed between 5 and 25% of its original thickness (before pressing). However, after the press is released, the panel essentially regains its original thickness.

The top layer may be is made of transparent material so that the middle layer can be seen clearly. The Interior layer is made of foamed material and may include an outlet in which an item may be placed for display. The Bottom layer may also be made of a transparent material according to the needs of the display. Optionally, the bottom layer can be semi transparent or even opaque.

A foamed or sponge plastic base material (material that is manufactured by Palziv of Ein Hanaziv, Israel, for example) may be coated with at least two very thin plastic films (for example PVC panels, ABS, polypropylene or transparent Perspex), one on each of its top and bottom surfaces. The coating material, texture, density, color and appearance may vary. The materials used are compatible with a host of other materials such as other foams, films, other polymers, textiles, adhesives.

In particular, contact glue is particularly suitable for fusing the ABS to the foamy middle layer.

These combinations create solid and very light products for the use of shelves applications, work surfaces, panels and other surfaces for exhibition and display needs for example. The apparatus has high mechanical and elastic stability and high resistance to wear and tear.

The interior foamed material which is flexible is in generally unbendable when attaching the plastic films on both sides as outer coating. The thickness of the coated product may be as thin as about 0.5mm, allowing it to be lightweight. However, the panel may be made somewhat flexible when the middle layer is sufficiently thin, but experiments have shown the panel to weaken when the overall thickness of the panel is less than 8mm.

The apparatus is designed to be solid and unbendable, to have enough thickness to enter a standard screw through without penetrating from the other end of the surface (which is a limitation in aluminum foam panels, that are too heavy at such thicknesses), to be easily processed in CNC machining and to be easily attached to another element. The apparatus has high chemical resistance; it is easily processed and used.

Reference is now made to Figures 4a, 4b illustrating the edges of light foamed structure 400 in accordance with a preferred embodiment of the present invention. The panel 400 has very smooth, pleasant edges so that there is no need for extra work, painting, or coating edges after the product 400 has been cut to size. The light foamed structure 400 may be easily cut in various curved shapes, without requiring finishing following the cutting. In sharp contrast, structures composed of honeycomb sandwiches, typically have very unsightly edges when cut in the same shapes, which makes it impractical to form them in such shapes.

Reference is now made to Figures 5a, 5b illustrating connection 500 between the edges of light foamed structures in accordance with a preferred embodiment of the present invention. Edges 514', 514" may be profiled in several shapes. The profiling is easily achieved by cutting and shaping foamed material that is flexible. Changing the shape of top and bottom surfaces 512' and 512" is relatively difficult, and is not needed due to the option of shaping the sandwiched foamed material. Therefore, profiling is done with no need for heavy machinery or for expensive process.

Figures 6a, 6b shows a reinforced structure 600 in which a slit 640 is made in the foam layer 610, into which a strong material such as a strip of aluminum 642 may be inserted such that it is completely embedded in the foam layer. A stiff layer 612' may then be stuck to the foam layer 610, preferably with a glue that essentially fuses foam layer 610 to layer 612'. Figure 7a shows a section of structure 700a, which is similar to in layer construction to structures 100-500, namely a foam layer adhered in between two inflexible layers.

Figure 7b shows a light foamed structure 700b, composed of a foamed layer 610 sandwiched between two layers 612', 612" of un-stretchable material, and further composed of a stretchable Iayer616' adhered to and covering an un-stretchable layers. Figure 7c shows a light foamed structure 700c, composed of a foamed layer 610 sandwiched between two layers 612', 612" of un-stretchable material, and further composed of stretchable layers 616' and 616" adhered to and covering un-stretchable layers 612', 612". Layers 616' and 616" may be identical or different from foam layer 610. Layer 616' and 616" may be identical or different from foam layer 610, and their material and thickness are selected and optimized to suit to the desired purpose of the structure 700b. They may be for example light and flexible polymeric foam, wood, or rubber.

Figure 8a illustrates a light foamed structure 800a such as shown in Figure 7a, in which the sizes of the un-stretchable layers 812', 812" are different from each other. Multiple structures such as this may be easily connected, similar to Figure 5.

Note that the structures 800a are connected by a base layer 816', which may be more flexible than layer 816'.

Figure 8b and Figure 8c illustrate structures similar to the one shown in Figure 8a, in folded rectangular 800b and triangular 800c forms respectively. Such forms may serve for example for easily showcasing exhibits from multiple directions.

Figure 9a shows a structure similar to the one shown in Figure 8a, folded and adapted into a briefcase 900; the suitcase is easily prepared from a planar structure in which the base layer is flexible, by folding it and attaching to the structure buckled straps at appropriate locations (not shown), and/or the edges may be reinforced and/or connected with hard fittings such as aluminum profiles 950, as is also shown in enlarged view in Fig. 9b. Figure 10 illustrates a 3-D character 1000 for display, composed of a light foamed structure. Such characters are much easier to prepare than 3-D display characters prepared essentially from aluminum.

Figure 1 shows insertion of an object such as an aluminum pipe 60 into a panel 1 100. The pipe 60 may be hollow and accommodate electrical wires etc.

Figure 12 shows the resilience of a panel 1200 hit with a hammer 70. The edge 1 1 14 is not appreciably affected by the blow and the panel 1200 is not vulnerable to being hit.

Figure 13 shows furniture 2000 made with panels 1300a-c.

Figure 14 shows a structure 1400 including shelf panels 1402c-f held by supporting panels 1402a-b.

The structures may include an additional layer which is magnetized; a magnetized layer may for example be situated between the foamed polymeric material and the unstrechable material. The structures can be connected to form superstructures with or without corners, for example store rooms, three- dimensional displays etc.

It should be clear that the description of the embodiments and attached Figures set forth in this specification serves only for a better understanding of the invention, without limiting its scope as covered by the following Claims.

It should also be clear that a person skilled in the art, after reading the present specification can make adjustments or amendments to the attached Figures and above described embodiments that would still be covered by the following Claims.

Claims

C L A I M S

1. A light foamed structure comprising: a top layer, a middle layer, a bottom layer and glue, wherein the middle layer comprises essentially elastic material selected from a group comprising polyethylene or EPDM foam and the top and bottom layers comprise essentially un- strethable meterial selected from a group comprising polypropylene, formaica, perspex, PVC, aluminum, wood or ABS, wherein the glue is strongly adherent to the top and bottom layers and to the middle layer, the strength of the adherence being a result of at least the pressing of the top layer and the bottom layer toward each other, to a roughly 1 -

40% distance of the top layer from the bottom layer compared to said distance before the pressing, wherein after the pressing the distance regains its distance before the pressing.

The structure of claim 1 , wherein the foam is cross-linked.

The structure of claim 1 or 2, wherein the foam comprises pores that mostly not interconnected, such that each pore is essentially completely encased in polymeric elastic material.

The structure of claim 1 or 2, wherein the foam has one or more of the charactersitics:

a density of 25-250 kg/m³; a dimensional stability of less than 2% change over 24 hours at 70°C for a 10mm thick specimen; temperature resistance of at least the range -60° to 90°C; and amenability to thermoforming, vacuum forming; CNC milling, lamination, die-cutting, splitting, butt welding, and combination with other foams, films, polymers and textiles by lamination or adhesion.

The structure of claim 3, wherein the foam has one or more of the charactersitics:

The structure of claim 1 or 2, wherein the structure has a thickness of at least 8mm.

The structure of claim 1 or 2, wherein the top layer and the bottom layer each have a thickness of at least 0.5 mm.

The structure of claim 1 or 2, wherein the structure is waterproof and floatable.

9. The structure of claim 1 or 2, wherein the structure allows insertion of screws or bolts or nails without prior drilling or forming a hole in the structure.

10. The structure of claim 1 or 2, wherein layer edges of the panel are each essentially homogeneous and smooth.

1 1. The structure of claim 10, wherein layer edges are homogeneous and smooth after cutting the structure.

12. The structure of claim 1 or 2, wherein the top and bottom layer are less strechable, less flexible and/or more rigid than the middle layer.

13. The structure of claim 1 or 2, wherein the top and/or bottom layer are ABS and the glue is contact glue.

14. The structure of claim 1 or 2, wherein the pressing of the top layer and the bottom layer toward each other, is to a 5-25% distance of the top layer form the bottom layer compared to said distance before the pressing.

15. The structure of claim 1 , capable of being printed on.