COMPOSITE BOARD
A panel comprising a honeycomb core is disclosed. In various embodiments, the honeycomb core is comprised of a folded material. In certain embodiments, the honeycomb core is comprised of an extruded material. A panel comprising a core comprised of a dimpled material is also disclosed. In at least one embodiment, the core is comprised of polyethylene and wood embedded in the polyethylene. The core comprises a first face and a second face opposite the first face and the deck board further comprises a first layer attached to the first face and a second layer attached to the second face. In various embodiments, the first layer and the second layer are thermally bonded to the core during a continuous manufacturing process. The panel can further comprise a decorative and/or performance layer bonded to the second layer.
1 . A manufactured deck board, comprising:
a core comprised of a folded material, wherein the core comprises a first face and a second face opposite the first face;
a first layer attached to the first face; and
a second layer attached to the second face.
2 . The manufactured deck board of claim 1 , wherein the core is comprised of a polymeric material and a cellulosic material embedded in the polymeric material.
3 . The manufactured deck board of claim 2 , wherein the cellulosic material comprises wood dust.
4 . The manufactured deck board of any one of claim 2 , wherein the polymeric material comprises a first polymeric material having a first melt temperature, and wherein the core comprises a second polymeric material having a second melt temperature that is higher than the first melt temperature.
5 . The manufactured deck board of any one of claim 1 , wherein the first layer is comprised of a polymeric material and a cellulosic material embedded in the polymeric material of the first layer.
6 . The manufactured deck board of claim 5 , wherein the cellulosic material of the first layer comprises wood dust.
7 . (canceled)
8 . (canceled)
9 . The manufactured deck board of any one of claim 1 , wherein the second layer comprises an outward face facing away from the core, and wherein the outward face comprises an embedded wood grain pattern.
10 . The manufactured deck board of any one of claim 1 , further comprising an outer layer attached to the second layer, wherein the outer layer comprises an embedded wood grain pattern.
11 . The manufactured deck board of claim 10 , wherein the core comprises a lateral core perimeter, and wherein the outer layer comprises an edge profile attached to the lateral core perimeter.
12 . The manufactured deck board of claim 1 , further comprising a lateral board perimeter and an edge profile attached to the lateral board perimeter.
13 . The manufactured deck board of claim 12 , wherein the edge profile comprises a cavity defined therein, and wherein the cavity faces the core.
14 . The manufactured deck board of claim 12 , wherein the core comprises a plurality of honeycomb cells, wherein each cell is defined by cell walls, and wherein the edge profile encloses voids between the edge profile and the cell walls.
15 . The manufactured deck board of claim 14 , wherein the core comprises a core perimeter, wherein the honeycomb cells along the core perimeter comprise perimeter cells, wherein the cell walls of one or more perimeter cells comprise a slot defined therein, and wherein the edge profile comprises a projection extending into the slot.
16 . The manufactured deck board of claim 15 , wherein the projection is secured to the core within the slot.
17 . The manufactured deck board of any one of claim 1 , further comprising a board perimeter and an edgeband attached to the board perimeter.
18 . The manufactured deck board of any one of claim 1 , further comprising a thermoformed perimeter comprising a thermoformed edge profile.
19 . The manufactured deck board of claim 18 , wherein the thermoformed edge profile comprises a rounded profile.
20 . The manufactured deck board of claim 18 , further comprising a board center plane extending through the core, wherein the thermoformed edge profile comprises a pinched profile, and wherein the second layer crosses the board center plane to form the pinched profile.
21 . The manufactured deck board of any one of claim 1 , wherein the core comprises a plurality of honeycomb cells.
22 . A manufactured deck board, comprising:
a core comprised of a dimpled material, wherein the core comprises a first face and a second face opposite the first face;
a first layer attached to the first face; and
a second layer attached to the second face.
23 - 184 . (canceled)