Composite board
A composite board is formed from binding a cover layer to a base layer, wherein the base layer has a composition comprising one or more of the following ingredients: magnesium oxide, recycled magnesium oxide, fibrous chips, wood chips, bamboo chips, chemical additive and water. A method of manufacturing the composite board includes providing the base layer, which includes preparing a semi-arid mixture of the above ingredients, and pouring the mixture through a funnel onto a conveyor belt. The conveyor belt passes the mixture through a series of rollers to remove excess liquid. The layer is cut into panels, which are heat before being sprayed with dried magnesium oxide. A binding agent is applied to one side of the base layer. The cover layer has a bottom surface which is then aligned and bonded to one side of the base layer.
1. A method of manufacturing a composite board, the steps comprising:
a. providing a single base layer panel having a substantially smooth first side and a second side opposite said first side, said providing of said single base layer panel includes the steps of:
i. preparing a chloride-free semi-arid mixture of high purity magnesium oxide, low purity magnesium oxide, fibrous chips, and chemical additive in an aqueous solution;
ii. pouring said semi-arid mixture through a funnel;
iii. dispensing said semi-arid mixture from said funnel onto a conveyor belt;
iv. passing the dispensed semi-arid mixture through a roller, where the roller is configured to press and spread said semi-arid mixture against the conveyor belt to a layer of desired uniform thickness;
v. pressing the layer through a compressor, where the compressor is configured to remove excess liquid from said layer; and
vi. cutting said compressed layer into at least one said base layer panel of predetermined length;
b. apply a binding agent to said first side of said single base layer panel;
c. providing a cover layer having a top and bottom surface; and
d. connecting the bottom surface of said cover layer to said first side of said single base layer panel.
2. The method of claim 1 wherein the high purity magnesium oxide has purity of at least 79%.
3. The method of claim 1 wherein the low purity magnesium oxide mixture further comprises recycled base layer panels.
4. The method of claim 1 wherein the fibrous chips are from the group consisting of wood and bamboo chips.
5. The method of claim 1 further comprises drying the at least one base layer.
6. The method of claim 1 further comprising heating the at least one base layer panel to a desired temperature.
7. The method of claim 6 wherein the at least one base layer panel is heated by solar energy.
8. The method of claim 1 further comprising:
passing the at least one single base layer panel through a jet, where the jet is configured to spray dry magnesium oxide on the at least one single base layer panel; and
stacking at least two single base layer panels.