US 12,377,645 B2
Composite panels and methods for making the same
Anthony Drevet, Chattanooga, TN (US); Philippe Erramuzpe, Augusta, GA (US); Shawn Liao, Taichung (TW); and Felix Herrera, Shanghai (CN)
Assigned to Columbia Insurance Company, Omaha, NE (US)
Filed by Columbia Insurance Company, Omaha, NE (US)
Filed on Apr. 27, 2023, as Appl. No. 18/140,217.
Application 18/140,217 is a continuation of application No. 17/236,571, filed on Apr. 21, 2021, granted, now 11,794,459.
Application 17/236,571 is a continuation in part of application No. 16/580,668, filed on Sep. 24, 2019, granted, now 12,109,790.
Claims priority of provisional application 63/018,300, filed on Apr. 30, 2020.
Claims priority of provisional application 63/013,953, filed on Apr. 22, 2020.
Claims priority of provisional application 62/735,607, filed on Sep. 24, 2018.
Prior Publication US 2023/0330980 A1, Oct. 19, 2023
This patent is subject to a terminal disclaimer.
Int. Cl. B32B 29/06 (2006.01); B32B 7/12 (2006.01); B32B 29/00 (2006.01); B32B 29/04 (2006.01)
CPC B32B 29/06 (2013.01) [B32B 7/12 (2013.01); B32B 29/005 (2013.01); B32B 29/04 (2013.01); B32B 2260/028 (2013.01); B32B 2260/046 (2013.01); B32B 2262/101 (2013.01); B32B 2264/10 (2013.01); B32B 2264/12 (2013.01); B32B 2307/546 (2013.01); B32B 2307/726 (2013.01); B32B 2307/732 (2013.01); B32B 2607/00 (2013.01)] 28 Claims
OG exemplary drawing
 
1. A composite panel comprising:
a rigid core comprising magnesium oxide, magnesium salt, and fibers;
a decor layer bonded to the rigid core, the decor layer composed of a paper impregnated with a melamine resin and comprising abrasion-resistant particles;
a protective layer disposed over the decor layer and comprising another paper impregnated with melamine resin, wherein the decor layer and the protective layer are directly laminated to the rigid core; and
a balancing layer composed of a paper impregnated with a melamine resin, the balancing layer disposed below the rigid core;
wherein corresponding overlapping portions of the decor layer and the rigid core are embossed, thus forming a three-dimensional texture on an exterior surface of the composite panel, and
wherein the rigid core comprises:
(i) at least 10% by weight and less than 40% by weight of magnesium oxide,
(ii) 5-34% by weight of magnesium salt, and
(iii) 20-50% by weight of fibers.