Composite Board

Abstract

A composite board and a method of manufacture thereof which board has a moulded front wall, a sheet insert which is attached to the front wall, a frame element which is attached to the front wall and the insert and an adhesive which acts between the front wall, the insert and the frame element.

1 - 29 . (canceled)  
   
   
       30 . A composite board which includes a moulded front wall, a sheet insert which is covered with a sealant and which is attached to the front wall, a frame element which is attached to the front wall and the insert and an adhesive which acts between the front wall, the insert and the frame element.  
   
   
       31 . A composite board according to  claim 30  wherein the front wall is made from a mouldable composition.  
   
   
       32 . A composite board according to  claim 31  wherein the mouldable composition includes a first resin and a catalyst.  
   
   
       33 . A composite board according to  claim 32  wherein the first resin is a thermosetting resin.  
   
   
       34 . A composite board according to  claim 31  wherein the mouldable composition includes a hydraulic binder.  
   
   
       35 . A composite board according to  claim 34  wherein the mouldable composition includes reinforcing.  
   
   
       36 . A composite board according to  claim 30  wherein the insert is made from an expanded or foamed material.  
   
   
       37 . A composite board according to  claim 36  wherein the material includes any one of polystyrene, polyurethane and phenolic foams.  
   
   
       38 . A composite board according to  claim 30  wherein the insert is made from an open-celled polymeric foam.  
   
   
       39 . A composite board according to  claim 38  wherein the polymeric foam is impregnated with a hydraulic binder.  
   
   
       40 . A composite board according to  claim 30  wherein the sealant is in the form of a thermoplastics polymer.  
   
   
       41 . A composite board according to  claim 30  wherein the adhesive includes a second resin and a catalyst.  
   
   
       42 . A composite board according to  claim 41  wherein the second resin is a thermosetting resin.  
   
   
       43 . A composite board according to  claim 30  which includes a reinforcing member which is submerged in the adhesive.  
   
   
       44 . A composite board according to  claim 30  which includes a backing sheet which covers the insert and the frame element.  
   
   
       45 . A composite board according to  claim 30  which includes a connecting layer which is applied to the insert and the frame element with which a second composite board is secured to the insert and the frame element.  
   
   
       46 . A method of manufacturing a composite board which includes the steps of: 
 A) applying a mouldable composition to a mould surface;    B) allowing the mouldable composition to set to form a front wall;    C) applying an adhesive to the front wall;    D) engaging a sheet insert and a frame element with the adhesive; and    E) allowing the front wall, insert and frame element to be attached to one another by the adhesive.    
   
   
       47 . A method according to  claim 46  wherein the mould surface is made from silicone rubber.  
   
   
       48 . A method according to  claim 46  which includes the step of submerging a reinforcing member in the adhesive.  
   
   
       49 . A method according to  claim 46  which includes the step of covering the sheet with a sealant.