The present disclosure relates generally to the timber industry. Particularly, the present disclosure relates to a ply-board and a method of production thereof.
BACKGROUND
[0002] Background description includes information that may be useful in understanding the present invention. It is not an admission that any of the information provided herein is prior art or relevant to the present invention, or that any publication specifically or implicitly referenced is prior art. [0003] Plywood is an engineered wood sheet material made up of fine layers or flimsy strands of wood veneers. It comprises a core of wood sandwiched between two veneers of wood. The basic step of manufacture consists of peeling, drying, and gluing to form a core followed by applying a face, and pressing to give the ply-board. Different types of ply-boards and their method of preparation are available in the literature, however, these ply-boards exhibits numerous drawbacks such as are non-durable, weak and are easily affected by routine problems such as termite attack, exposure to wet or moist weather resulting in opening up of the board, making them fluffy and loose. These ply-wood exhibit very low tensile strength and are of no commercial use, particularly, where there is a risk of exposure to high temperature and strong chemical compounds. [0004] There is, therefore, an unmet need in the art to develop a new and improved ply-board and method of production thereof, that may overcome the problems associated with the existing ply-board and method of productions thereof. The present invention satisfies the existing as well as others needs.
OBJECTS
[0005] An object of the present disclosure is to provide a new and improved ply-board.
[0006] Another object of the present disclosure is to provide a ply-board that is durable and exhibits high strength.

[0007] Another object of the present disclosure is to provide a method of production of a ply-board.
[0008] Another object of the present disclosure is to provide a method of production of ply-board that is economical and easy to carry out.
SUMMARY OF THE INVENTION
[0009] This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the detailed description section. This summary is not intended to identify key features or essential features of the subject matter, nor is it intended to be used as an aid in determining the scope of the subject matter.
[0010] The present disclosure relates generally to the timber industry. Particularly, the present disclosure relates to a ply-board and a method of production thereof.
[0011] An aspect of the present disclosure relates to a method of production of a ply-board 100, the method including the steps of: (a) stacking a plurality of wooden sheets 104 using a cyanoacrylate and/or resorcinol formaldehyde based compound 106 to obtain a stacked wooden sheet; (b) compacting the stacked wooden sheet to obtain a core 102; (c) binding at least a part of the core 102 with a plastic wire mesh 108 to obtain a mesh bound core 110; and (d) placing a face veneer 112 on the mesh bound core 110 and pressing to obtain a ply-board 100. In an embodiment, the plastic wire mesh is made of any or a combination of a thermoplastic polymer and a thermosetting polymer. In an embodiment, the polymer is selected from any or a combination of polyethylene, polypropylene and the like. In an embodiment, the plastic wire mesh is made of a recycled plastic. In an embodiment, pressing in step (d) is performed by any of a cold pressing and a hot pressing. In an embodiment, the hot pressing is performed at a temperature ranging from 120°C to 200°C for a time period ranging from 2 min to 25 min. In an embodiment, the hot pressing melts the plastic wire mesh and coats at least a part of the core.

[0012] Another aspect of the present disclosure relates to a ply-board 100 including: a core 102 comprising a compacted stack of wooden sheets 104 adhered to each other using a cyanoacrylate and/or resorcinol formaldehyde based compound 106, wherein at least a part of said core 102 being bound by a plastic wire mesh 108 to obtain a mesh bound core 110; and a face veneer 112 is placed on the mesh bound core 110. In an embodiment, the plastic wire mesh is made of any or a combination of a thermoplastic polymer and a thermosetting polymer. In an embodiment, the polymer is selected from any or a combination of polyethylene, polypropylene and the like. In an embodiment, the plastic wire mesh is made of a recycled plastic.
[0013] Other aspects of the invention will be set forth in the description which follows, and in part will be apparent from the description, or may be learnt by the practice of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 and FIG. 2 illustrates arrangements of the proposed ply-wood, in accordance with embodiments of the present disclosure
DETAILED DESCRIPTION OF THE INVENTION
[0015] The following is a detailed description of embodiments of the disclosure. The embodiments are in such detail as to clearly communicate the disclosure. However, the amount of detail offered is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present disclosure.
[0016] All publications herein are incorporated by reference to the same extent as if each individual publication or patent application were specifically and individually indicated to be incorporated by reference. Where a definition or use of a term in an incorporated reference is inconsistent or contrary to the definition of that term provided herein, the definition of that term provided herein applies and the definition of that term in the reference does not apply.

[0017] Reference throughout this specification to "one embodiment" or "an embodiment" means that a particular feature, structure or characteristic described in connection with the embodiment is included in at least one embodiment. Thus, the appearances of the phrases "in one embodiment" or "in an embodiment" in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments.
[0018] In some embodiments, numbers have been used for quantifying weights, percentages, ratios, and so forth, to describe certain embodiments of the invention and are to be understood as being modified in some instances by the term "about." Accordingly, in some embodiments, the numerical parameters set forth in the written description are approximations that can vary depending upon the desired properties sought to be obtained by a particular embodiment. In some embodiments, the numerical parameters should be construed in light of the number of reported significant digits and by applying ordinary rounding techniques. Notwithstanding that the numerical ranges and parameters setting forth the broad scope of some embodiments of the invention are approximations, the numerical values set forth in the specific examples are reported as precisely as practicable. The numerical values presented in some embodiments of the invention may contain certain errors necessarily resulting from the standard deviation found in their respective testing measurements.
[0019] Various terms as used herein are shown below. To the extent a term used is not defined below, it should be given the broadest definition persons in the pertinent art have given that term as reflected in printed publications and issued patents at the time of filing.
[0020] As used in the description herein, the meaning of "a," "an," and "the" includes plural reference unless the context clearly dictates otherwise. Also, as used in the description herein, the meaning of "in" includes "in" and "on" unless the context clearly dictates otherwise.

[0021] Unless the context requires otherwise, throughout the specification which follow, the word "comprise" and variations thereof, such as, "comprises" and "comprising" are to be construed in an open, inclusive sense that is as "including, but not limited to."
[0022] The recitation of ranges of values herein is merely intended to serve as a shorthand method of referring individually to each separate value falling within the range. Unless otherwise indicated herein, each individual value is incorporated into the specification as if it were individually recited herein. [0023] All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g. "such as") provided with respect to certain embodiments herein is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention. No language in the specification should be construed as indicating any non-claimed element essential to the practice of the invention.
[0024] Groupings of alternative elements or embodiments of the invention disclosed herein are not to be construed as limitations. Each group member can be referred to individually or in any combination with other members of the group or other elements found herein. One or more members of a group can be included in, or deleted from, a group for reasons of convenience and/or patentability. When any such inclusion or deletion occurs, the specification is herein deemed to contain the group as modified.
[0025] The description that follows, and the embodiments described therein, is provided by way of illustration of an example, or examples, of particular embodiments of the principles and aspects of the present disclosure. These examples are provided for the purposes of explanation, and not of limitation, of those principles and of the disclosure.
[0026] It should also be appreciated that the present disclosure can be implemented in numerous ways, including as a system, a method or a device. In this specification, these implementations, or any other form that the invention may

take, may be referred to as processes. In general, the order of the steps of the disclosed processes may be altered within the scope of the invention. [0027] The headings and abstract of the invention provided herein are for convenience only and do not interpret the scope or meaning of the embodiments. [0028] The following discussion provides many example embodiments of the inventive subject matter. Although each embodiment represents a single combination of inventive elements, the inventive subject matter is considered to include all possible combinations of the disclosed elements. Thus if one embodiment comprises elements A, B, and C, and a second embodiment comprises elements B and D, then the inventive subject matter is also considered to include other remaining combinations of A, B, C, or D, even if not explicitly disclosed.
[0029] The present disclosure relates generally to the timber industry. Particularly, the present disclosure relates to a ply-board and a method of production thereof.
[0030] The present disclosure is on the premise of a surprising discovery that, when at least a part of the core of the plywood is bind with a plastic wire mesh it provide additional strength to the ply-wood (as compared to ply-boards with layering), making them more durable, resistant towards termites, moisture and other environmental conditions.
[0031] An aspect of the present disclosure relates to a method of production of a ply-board 100, the method including the steps of: (a) stacking a plurality of wooden sheets (104) using a cyanoacrylate and/or resorcinol formaldehyde based compound 106 to obtain a stacked wooden sheet; (b) compacting the stacked wooden sheet to obtain a core 102; (c) binding at least a part of the core 102 with a plastic wire mesh 108 to obtain a mesh bound core 110; and (d) placing a face veneer 112 on the mesh bound core 110 and pressing to obtain a ply-board 100. [0032] In an embodiment, the plurality of wooden sheets is obtained by peeling logs of wood. In an embodiment, the plurality of wooden sheets is dried before stacking to remove any moisture present in them. In an embodiment, the peeling of logs of wood may be performed by a spindleless peeling machine.

However, a person skilled in the art would appreciate that any other conventional machine/method(s) can be utilized to serve the intended purpose. [0033] In an embodiment, the binding may be done by coiling the plastic wire mesh over at least part of the core. In an embodiment, the plastic wire mesh is bound along the length of the core. In an embodiment, the plastic wire mesh is bound over the entire core. In an embodiment, the entire core is covered with the plastic wire mesh.
[0034] In an embodiment, the cyanoacrylate and/or resorcinol formaldehyde based compound acts as an adhesive to adhere a plurality of wooden sheets in the stack. These compounds are safe and preferred over other related compounds such as urea-formaldehyde that are unsafe and banned in some countries. [0035] In an embodiment, the plastic wire mesh is made of any or a combination of a thermoplastic polymer and a thermosetting polymer. In an embodiment, the polymer is selected from any or a combination of polyethylene, polypropylene and the like. In an embodiment, the plastic wire mesh is made of a recycled plastic. In an embodiment, the plastic wire mesh is obtained by the process comprising the steps of: (i) melting a recycled plastic to obtain a melt, (ii) molding the melt into plastic wires, and finally (iii) forming plastic wire mesh with the plastic wires. In an embodiment, diameter of the wire ranging from 0.3 mm to 3.0 mm, preferably, from 0.5 mm to 2.0 mm, and more preferably, from 0.5 mm to about 1.0 mm. In an embodiment, the diameter of the wire is 0.55 mm. [0036] In an embodiment, pressing in step (d) is performed by any of a cold pressing and a hot pressing. In an embodiment, the hot pressing is performed at a temperature ranging from 120°C to 200°C for a time period ranging from 2 min to 25 min. In an embodiment, the hot pressing is performed at a temperature ranging from 140°C to 170°C for a time period ranging from 2 min to 20 min. In an embodiment, the pressure during the pressing ranges from 0.5 mpa to about 2.5 mpa, preferably, 0.8 mpa to about 1.6 mpa. In an embodiment, the hot pressing melts the plastic wire mesh and coats at least a part of the core. In an embodiment, the pressing is performed by an electric press machine. However, a person skilled

in the art would appreciate that any other press machine(s) can be utilized to serve the intended purpose.
[0037] In an embodiment, the steps (c) and (d) may be performed more than once to give two or more bindings of with plastic wire mesh. [0038] In an embodiment, the hot pressing melts the plastic wire mesh to coat the core with a plastic coating. This plastic coating provides protection to the ply-board from termites, water and any environmental damage. In an embodiment, each of the plastic coatings may be bound to each other by adhesive forces. [0039] In an embodiment, in addition to the face veneer, a back veneer may also be employed in step (d). In an embodiment, the core bound by the plastic wire mesh may be sandwiched between a face veneer and a back veneer. [0040] In an embodiment, the step (d) of the method as recited herein may be followed by a finishing step. The finishing step may include any of the steps well-known in the art for delivery of finished wood, including trimming, painting, polishing, sizing, sanding, layering, treating, or combinations thereof. [0041] Another aspect of the present disclosure relates to a ply-board 100 including: a core 102 comprising a compacted stack of wooden sheets 104 adhered to each other using a cyanoacrylate and/or resorcinol formaldehyde based compound 106, wherein at least a part of said core 102 being bound by a plastic wire mesh 108 to obtain a mesh bound core 110; and a face veneer 112 is placed on the mesh bound core 110. In an embodiment, the plastic wire mesh is made of any or a combination of a thermoplastic polymer and a thermosetting polymer. In an embodiment, the polymer is selected from any or a combination of polyethylene, polypropylene and the like. In an embodiment, the plastic wire mesh is made of a recycled plastic.
[0042] Referring to FIG. 1, the disclosed ply-wood 100 comprises: a core 102 comprising a compacted stack of wooden sheets 104-1, 104-2 and 104-3, adhered to each other using a cyanoacrylate and/or resorcinol formaldehyde based compound layers 106-1 and 106-2, wherein at least a part of said core 102 being bound by plastic wire meshes 108-1 and 108-2 to obtain a mesh bound core 110; and face veneers 112-1 and 112-2 are placed on the mesh bound core.

[0043] Referring to FIG. 2, the disclosed ply-wood 200 comprises: a core 102 comprising a compacted stack of wooden sheets 104-1, 104-2 and 104-3, adhered to each other using a cyanoacrylate and/or resorcinol formaldehyde based compound layers 106-1 and 106-2, wherein at least a part of said core 102 being bound by a plastic wire mesh 108 to obtain a mesh bound core 202; and face veneers 112-1 and 112-2 are placed on the mesh bound core 202. [0044] In an embodiment, the ply-board 100 comprising of a core 102, at least one protective plastic coating 108, and at least one face veneer 112; wherein the plastic coating is formed by a plastic wire mesh obtained from recycled plastic.
[0045] In an embodiment, the ply-board 100 comprising of a core 102, at least one protective plastic coating 108, a face veneer 112-1 and a back veneer 112-2; wherein the plastic coating is formed by a plastic wire mesh obtained from recycled plastic.
[0046] In an embodiment, the ply-board has a density of 700 kg/m3 to 1000 kg/m3. In an embodiment, the ply-board has a density of 800 kg/m3 to 825 kg/m3. In an embodiment, the ply-board has a moisture content of 6% to 10%. In an embodiment, the ply-board has water absorption less than 5%. In an embodiment, the ply-board obtained by the disclosed method is termite protected, less flammable and water proof. In an embodiment, the ply-board is economical, and made of sustainable components specifically recycled plastic waste. In an embodiment, the ply-board possesses high tensile strength and is more durable. In an embodiment, the ply-board does not undergo wear and tear thereby avoiding frequent repair and replacement.
[0047] While the foregoing describes various embodiments of the disclosure, other and further embodiments of the disclosure may be devised without departing from the basic scope thereof. The invention is not limited to the described embodiments, versions or examples, which are included to enable a person having ordinary skill in the art to make and use the invention when combined with information and knowledge available to the person having ordinary skill in the art.

ADVANTAGES
[0048] The present disclosure provides a new and improved ply-board. [0049] The present disclosure provides a ply-board that is reinforced with plastic.
[0050] The present disclosure provides a ply-board that is durable and exhibits high strength.
[0051] The present disclosure provides a ply-board that is resistant to termite and moisture.
[0052] The present disclosure provides a ply-board that is chemically inert and less flammable.
[0053] The present disclosure provides a method of production of a ply-board.
[0054] The present disclosure provides a method of production of ply-board that is economical and easy to carry out.

We Claim:

1. A method of production of a ply-board (100), the method comprising the
steps of:
(a) stacking a plurality of wooden sheets (104) using a cyanoacrylate and/or resorcinol formaldehyde based compound (106) to obtain a stacked wooden sheet;
(b) compacting the stacked wooden sheet to obtain a core (102);
(c) binding at least a part of the core (102) with a plastic wire mesh (108) to obtain a mesh bound core (110); and
(d) placing a face veneer (112) on the mesh bound core (110) and pressing to obtain a ply-board (100).

2. The method as claimed in claim 1, wherein the plastic wire mesh is made of any or a combination of a thermoplastic polymer and a thermosetting polymer.
3. The method as claimed in claim 2, wherein the polymer is selected from any or a combination of polyethylene, polypropylene and the like.
4. The method as claimed in claim 1, wherein the plastic wire mesh is made of a recycled plastic.
5. The method as claimed in claim 1, wherein pressing in step (d) is performed by any of a cold pressing and a hot pressing.
6. The method as claimed in claim 5, wherein the hot pressing is performed at a temperature ranging from 120°C to 200°C for a time period ranging from 2 min to 25 min.
7. The method as claimed in claim 6, wherein the hot pressing melts the plastic wire mesh and coats at least a part of the core.
8. A ply-board (100) comprising:
a core (102) comprising a compacted stack of wooden sheets (104) adhered to each other using a cyanoacrylate and/or resorcinol formaldehyde based compound (106), wherein at least a part of said core

(102) being bound by a plastic wire mesh (108) to obtain a mesh bound
core (110); and
a face veneer (112) is placed on the mesh bound core (110). The ply-board as claimed in claim 8, wherein the plastic wire mesh is made of any or a combination of a thermoplastic polymer and a thermosetting polymer.
The ply-board as claimed in claim 9, wherein the plastic wire mesh is made of a recycled plastic.