1. A container flooring comprising a core layer and symmetrical surface layers on both surfaces of the core panel each comprising a resin-impregnated wood veneer layer.
2. The container flooring of claim 1 wherein the resin-impregnated wood veneer layer comprises poplar, pine, eucalyptus, spruce or fir wood.
3. The container flooring of claim 1 wherein the surface layers each comprise, in sequence from inside toward outside, at least one layer of perpendicular-grained phenol-formaldehyde resin-impregnated wooden veneer, and at least 2 layers of parallel-grained resin-impregnated wooden veneers.
4. The container flooring of claim 1 wherein the resin-impregnated wooden veneers have been dried under low temperature.
5. The container flooring of claim 1 wherein the core layer comprises a structural strand-based panel or a multi-layer wood veneer panel.
6. The container flooring of claim 5 wherein the core layer comprises multiple layers of parallel-grained and perpendicular-grained veneers assembled in accordance with layout requirements of container flooring to form the core layer.
7. The container flooring of claim 6 wherein the core layer comprises 11 to 13 layers of parallel-grained and perpendicular-grained veneers.
8. The container flooring of claim 1 wherein each surface layer further comprises an outer hardwood veneer layer.
9. The container flooring of claim 1 wherein each surface layer further comprises an outer layer of resin-impregnated paper as the outermost surface layer.
10. The container flooring of claim 1 wherein each surface layer farther comprises a layer of resin-impregnated bamboo curtain sheet or woven-mat sheet.
11. A method of manufacturing a container flooring comprising a core layer and surface layers on both surfaces of the core panel each comprising a resin-impregnated wood veneer layer, comprising the step of impregnating the wood veneer with a resin, symmetrically assemble the surface layers with the core layer to form a mat; consolidate the assembled mat by hot-pressing; gradually reducing the press pressure in steps for degassing and relieving the press pressure.
12. The method of claim 11 wherein the surface layers further comprises a resin-impregnated paper or a resin-impregnated bamboo layer, comprising the step of impregnating the paper or bamboo layer with a resin.
13. The method of claim 11 comprising the steps of: drying the wood veneer to a moisture content of less than about 12%, spread resin on both sides with the spread rate of 250 to 350 gm2 (resin solid content is 40% to 50%); impregnate the wood veneer with resin with the resin retention rate of 15% to 50% and then are conditioned or dried under low temperature.
14. The method of claim 12 comprising the steps of: drying the bamboo layer to a moisture content of less than about 12%, diluting the resin to a solid content of 30% to 36%, impregnating the bamboo with resin under the normal pressure with the resin retention of 7% to 10%.
15. The method of claim 11 comprising the hot-pressing conditions comprise a press temperature from 125 to 150\xb0 C. and press pressure from 2.0 to 4.0 MPa for 5 to 10 minutes.
16. The method of claim 11 wherein the resin impregnation step comprises a direct pressurized treatment; a vacuum and pressurized treatment; a pressurized, vacuum and pressurised treatment; or a combination of repeat vacuum and pressurized treatments to induce the resin to penetrate into cell lumens and cell walls of the veneers.
17. The method of claim 11 wherein the core layer comprises a strand layer and is pre-pressed prior to mat consolidation.
The claims below are in addition to those above.
All refrences to claim(s) which appear below refer to the numbering after this setence.
1. A modular therapy mattress comprising:
a base of high density foam,
n upper panel of high density foam attached to the base in an upper body and head region of the mattress, the upper panel having a lower firmness than the base,
one or more inserts fitted to the base in a trunk, lower leg or heel region of the mattress, wherein the inserts comprise one or more of:
(iv) a gel infused visco-elastic memory foam panel bonded to a foam panel base, the foam panel base having a higher firmness than the gel infused visco-elastic memory foam panel,
(v) a visco-elastic memory foam panel bonded to a foam panel base, the foam panel base having a higher firmness than the visco-elastic memory foam panel,
(vi) an air cell panel comprising a plurality of air cells formed from a generally flat base sheet and a top sheet both made from an air impervious material, the top sheet molded to form the plurality of air cells fixed to the base sheet around bottom edges of the air cells, and
a cover fully enveloping the base, the upper panel and the insert or inserts fitted to the base.
2. A modular therapy mattress as claimed in claim 1, wherein the width of the air cell panel is less than the width of the base and the upper panel, in use the air cell panel mounted centrally between longitudinal edges of the base.
3. A modular therapy mattress as claimed in claim 2, wherein the width of the air cell mattress is 20 mm to 200 mm, or 20 mm to 150 mm, or 20 mm to 100 mm, or 50 mm to 100 mm or about 80 mm less than the width of the base.
4. A modular therapy mattress as claimed in claim 2, wherein the width of the upper panel, the gel infused visco-elastic memory foam panel, and the visco-elastic memory foam panel is approximately the same as the width of the base.
5. A modular therapy mattress as claimed in claim 1, wherein the thickness of the base is less than the thickness of the inserts.
6. A modular therapy mattress as claimed in claim 5, wherein the thickness of the inserts is approximately 1 to 2 times the thickness of the base, or approximately 1.5 times the thickness of the base.
7. A modular therapy mattress as claimed in claim 1, wherein the thickness of the gel infused visco-elastic memory foam panel is similar to the thickness of the foam panel base to which it is bonded, andor the thickness of the visco-elastic memory foam panel is similar to the thickness of the foam panel base to which it is bonded.
8. A modular therapy mattress as claimed in claim 1, wherein in use the gel infused visco-elastic memory foam panel is fitted to the base in the trunk region of the mattress.
9. A modular therapy mattress as claimed in claim 1, wherein in use the visco-elastic memory foam panel is fitted to the base in the lower leg or heel region of the mattress.
10. A modular therapy mattress as claimed in claim 1, wherein in use a said visco-elastic memory foam panel is fitted to the base in the lower leg or heel region of the mattress, and a said visco-elastic memory foam panel is fitted to the base in the trunk region of the mattress, and wherein the density of the visco-elastic memory foam in the truck region of the mattress is greater than the density of the visco-elastic memory foam in the lower leg or heel region of the mattress.
11. A modular therapy mattress as claimed in claim 1, wherein in use the air cell panel is fitted to the lower leg or heel region.
12. A modular therapy mattress as claimed in claim 1, comprising one or more said air cell panels, in use the air cell panels fitted to the trunk region and the lower leg or heel region.
13. A modular therapy mattress as claimed in claim 1, wherein the base thickness is about 50 mm or 2 inches and the insert thickness is about 75 mm or 3 inches, the overall thickness of the mattress being about 125 mm or 5 inches.
14. A modular therapy mattress as claimed in claim 1, wherein the upper body and head region is approximately 25% of the length of the mattress, the lower leg or heel region is approximately 25% of the length of the mattress, and the trunk region located in between the upper body and head region and the lower leg or heel region is approximately 50% of the length of the mattress.
15. A modular therapy mattress as claimed in claim 1, comprising three said inserts, the inserts having approximately the same length, two inserts of the same construction fitted to the base in the trunk region and one insert fitted to the base in the lower leg or heel region.
16. A modular therapy mattress as claimed in claim 1, comprising three said inserts fitted to the base in the lower leg or heel region and the trunk region, each insert comprising an air-cell panel.
17. A modular therapy mattress as claimed in claim 1, wherein with the insert or inserts fitted to the base the overall thickness of the mattress in the upper body and head region, the trunk region and the lower leg or heel region is substantially the same.
18. A modular therapy mattress as claimed in claim 1, wherein the cover is formed from a material having sufficient stiffness to structurally maintain the position of the inserts on the base of the mattress.
19. A modular therapy mattress as claimed in claim 4, wherein the cover has a substantially constant width and height so that the cover is looser over the air cell panel than in other regions of the mattress to allow for lowered surface tension in the cover and greater immersion in the air cells of the air cell panel.
20. A modular therapy mattress as claimed in claim 1, wherein the hardness of the high density foam forming the base is approximately twice the hardness of the high density foam forming the upper panel.