# US 2019/0168484 A1 · Composite panel and method of forming same > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2019/0168484 A1 - Document ID: US20190168484A1 - Status: Published application - Kind: A1 - Application number: 16/259,217 - Filed: 2019-01-28 - Published: 2019-06-06 - Earliest claimed: 2016-07-27 - Assignees: Corruven Canada Inc. - Applicants: Corruven Canada Inc. - Inventors: Alain BELANGER; Daniel BEAUREGARD-LONG; Scott PHILIPPE; Christian JALBERT - Web page: https://patentgrep.com/patent/US20190168484A1 ## CPC - B32B 7/12: using interposed adhesives or interposed materials with bonding properties - B27D 1/06: Manufacture of central layers; Form of central layers {(see also B27M3/002 and B27M3/0026)} - B27D 1/08: Manufacture of shaped articles; Presses specially designed therefor - B31F 1/20: Corrugating; Corrugating combined with laminating to other layers - B31F 1/2895: {from corrugated webs having corrugations of particular shape} - B32B 21/06: of paper or cardboard - B32B 21/14: comprising wood board or veneer - B32B 29/02: next to a fibrous or filamentary layer - B32B 29/08: Corrugated paper or cardboard - E04C 2/16: of fibres, chips, vegetable stems, or the like - E04C 2/246: {combinations of materials fully covered by E04C2/16 and E04C2/20} - E04C 2/322: {with parallel corrugations} - B32B 37/12: characterised by using adhesives - B32B 38/06: Embossing - B32B 2317/12: Paper, e.g. cardboard - B32B 2317/122: Kraft paper - B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM - B27D: WORKING VENEER OR PLYWOOD (applying liquids or other fluent materials to surface in general B05; grinding, sanding, or polishing of wood B24; applying adhesives or glue to surfaces of wood B27G11/00; manufacture of veneer B27L5/00) - B31F: MECHANICAL WORKING OR DEFORMATION OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER (making layered products not composed wholly of paper or cardboard B32B) - E04C: STRUCTURAL ELEMENTS; BUILDING MATERIALS (for bridges E01D; specially designed for insulation or other protection E04B; elements used as building aids E04G; for mining E21; for tunnels E21D; structural elements with broader range of application than for building engineering F16, particularly F16S) ## Abstract A composite panel includes a sheet having layers. At least two of the layers are kraft paper. The layers re stacked on each other and adhered together with a resin. The sheet is corrugated with alternating peaks and valleys disposed sequentially along an axis of the sheet. Each peak has a plateau and each valley has a base. Each of the plateaus and the bases lies in a plane being substantially parallel to the axis of the one sheet. ## Claims ### Claim 1 A composite panel, comprising: a sheet having layers, at least two of the layers being kraft paper, the layers being stacked on each other and adhered together with a resin, the sheet being corrugated with alternating peaks and valleys disposed sequentially along an axis of the sheet, each peak having a plateau and each valley having a base, each of the plateaus and the bases lying in a plane being substantially parallel to the axis of the one sheet. ### Claim 2 (depends on 1) The composite panel as defined in claim 1, wherein the layers of the sheet include only two layers of kraft paper stacked one over the other and adhered directly together with the resin. ### Claim 3 (depends on 1) The composite panel as defined in claim 1, wherein the layers of the sheet include a layer of wood veneer having wood fibers defining a porous wood matrix extending into the wood veneer from each of a first and a second side of the wood veneer, the resin being applied to both of the first and second sides, the resin filling pores of the wood matrix, the layers of kraft paper at least partially covering both the first and second sides of the wood veneer and adhered thereto with the resin. ### Claim 4 (depends on 3) The composite panel as defined in claim 3, wherein a majority of the wood fibers of the layer of wood veneer are aligned along a single direction. ### Claim 5 (depends on 3) The composite panel as defined in claim 3, wherein each of the layers of kraft paper includes paper fibers, a majority of the paper fibers being oriented transverse to the wood fibers. ### Claim 6 (depends on 3) The composite panel as defined in claim 3, wherein each of the layers of the kraft paper have paper fibers, a majority of the paper fibers being aligned in a direction transverse to the axis of the sheet. ### Claim 7 (depends on 1) The composite panel as defined in claim 1, wherein each plateau and each base has a length defined along the axis of the sheet of about 11 mm. ### Claim 8 (depends on 1) The composite panel as defined in claim 1, wherein the sheet has a thickness measured transverse to the axis of the sheet, the thickness being about 19 mm. ### Claim 9 (depends on 1) The composite panel as defined in claim 1, wherein adjacent plateaus are separated by a distance measured along the axis of the sheet of about 50 mm. ### Claim 10 (depends on 1) The composite panel as defined in claim 1, wherein the sheet has intermediate segments interconnecting the peaks and valleys, each intermediate segment having a first joint portion at a first end thereof connected to one of the plateaus, and a second joint portion at a second end of the intermediate segment connected to one of the bases, the first joint portion being curved and having a first radius of curvature, the second joint portion being curved and having a second radius of curvature. ### Claim 11 (depends on 11) The composite panel as defined in claim 11, wherein the first radius of curvature is different than the second radius of curvature. ### Claim 12 (depends on 11) The composite panel as defined in claim 11, wherein the first radius of curvature is about 5.7° and the second radius of curvature is about 3.0°. ### Claim 13 (depends on 10) The composite panel as defined in claim 10, wherein an angle of corrugation is defined between a plane perpendicular to the axis of the sheet and each intermediate segment, the angle of corrugation being about 26°. ### Claim 14 (depends on 1) The composite panel as defined in claim 1, the panel being rolled up. ### Claim 15 A method of forming a structural composite panel, comprising: stacking layers and adhering the layers together to form a sheet, at least two of the layers being kraft paper; and corrugating the sheet along an axis to form alternating peaks and valleys disposed sequentially along the axis, each peak having a plateau and each valley having a base, each of the plateaus and the bases lying in a plane being substantially parallel to the axis of the sheet. ### Claim 16 (depends on 15) The method as defined in claim 15, wherein stacking the layers includes stacking only the layers of kraft paper directly against each other and adhering them together. ### Claim 17 (depends on 15) The method as defined in claim 15, wherein stacking the layers includes stacking a layer of wood veneer having wood fibers between the layers of kraft paper adhered to both sides of the wood veneer. ### Claim 18 (depends on 17) The method as defined in claim 17, wherein stacking the layer of wood veneer includes orienting a majority of the wood fibers of the layer of wood veneer along a single direction. ### Claim 19 (depends on 18) The method as defined in claim 18, wherein stacking the layers includes orienting a majority of paper fibers of each of the layers of kraft paper transverse to the wood fibers. ### Claim 20 (depends on 15) The method as defined in claim 15, wherein stacking the layers includes orienting a majority of paper fibers of each of the layers of kraft paper in a direction transverse to the axis of the sheet. ### Claim 21 (depends on 15) The method as defined in claim 15, corrugating the sheet includes orienting segments connecting adjacent plateaus and bases at an angle of corrugation, the angle of corrugation being defined between a plane perpendicular to the axis and each segment, the angle of corrugation being about 26°.