Title of Invention

REINFORCEDENCAPSULATED COMPOSITE PANEL AND METHOD FOR MAKING THE SAME

Abstract

Technical field of Reinforced Encapsulated Composite Panel is Wood Science & Technology and further belongs to the Woodworking industry. Technical problem with the available panels are that they have high expansion coefficients, do not have structural and dimensional stability, do not have water and vapour resistance and move significantly with changes in temperature and humidity. The solution to this is made in the form of reinforced encapsulated composite panel using thermally stable materials such as ceramic, cement tiles, reinforced cellulose panels and stone with heat insulating materials like wood in the same panel with a water resistant encapsulation interface which can be sanded, calibrated and machined. The reinforced and encapsulated composite panel is then covered with a decorative surface such as wood, laminate, leather, metal and inlay and then coated with suitable scratch and abrasion resistant coatings. Such panels would fmd application as wall cladding and floor coverings. Original FIG. 12 illustrates the cross section of a reinforced encapsulated composite panel with profiled edges and an encapsulated decorative layer.

Full Text

TECHNICAL FIELD OF INVENTION Wood Science & Technology and further belongs to woodworking industry. PRIOR ART WITH SHORT COMINGS The problems associated with sub-floor moisture and liquid spillage on floorings and coverings using cellulose based foundation layer materials are well known. Currently available wooden flooring and laminate flooring using substrates like high density fibreboard, chipboard, plywood or solid lumber itself suffer from serious dimensional stability problems when exposed to high levels of humidity or to moisture while cleaning, during spillage of liquids etc. Although many manufacturers have adopted lock designs with minimal gap between planks, fluids still manage to seep through the joints. When the fluids seep through, the plank warps increasing the gaps and the problem then becomes cumulative and upwardly exponential. Application of waxes and protective coatings on the edges is not very effective against vapour as such coatings can only be applied very thin since thicker coatings distort the straight line edge finish of the flooring. While many products have appeared in the market recently, which use virgin or recycled thermoplastic vinyl substrates, such products are not only harmful to the environment, but also have low thermal stability, low hardness and poor impact resistance. The use of thermoplastic foundation layers for flooring and panels with higher thickness is limited due to the high cost of the resins. Lower thickness on the other hand lends itself to less dimensional stability of the flooring tiles or panels due to the reduced value of section modulus. Stone, cement and ceramic substrates are dimensionally stable as also moisture / vapour resistant. They are however available only in certain finishes due to processing limitations. Ceramic and stone substrates also have to be installed with 2-4 mm joints of filler material. Unlike wooden panels, commercially available ceramic and stone materials are not dimensionally precise due to the high costs to be incurred in calibrating and machining them. Although ceramic tiles with wood-like printed finishes have appeared in the market, the reproduction of the natural characteristics of wood is very poor. Such tiles have also to be laid with the 2-5 mm filler gaps and hence do not at all look like wooden planks when laid. Further, such tiles cannot be produced with inlays due to the high temperatures used in the glazing process during manufacture. It is known to those experienced in the art that directly using stone or ceramic substrates as foundation layers for wooden flooring/ wood inlay flooring is extremely difficult and expensive due to the hardness of these materials and high processing costs encountered in precisely calibrating and machining such materials. The substrate surfece should have an accuracy of 0.1 mm in order to achieve a durable adhesive joint. Ceramic and stone products are extremely hard necessitating the use of expensive abrasive materials for precise calibration. It is also extremely expensive to shape the edges of stone and ceramic foundation layer tiles with locking profiles and tongue-groove profiles. Meanwhile, providing a minimal hairline gap between panels is important for attaining better looks and aesthetic value for the flooring or wall panels. PROBLEMS WITH THE EXISTING ART Technical problem with the available panels are that they have high expansion coefficients, do not have structural and dimensional stability, do not have water and vapour resistance and move significantly with changes in temperature and humidity. As seen in: Alvin E.Witt et al., U.S Pat No. 5,976,689 discloses a Coated Synthetic Resin Board tile. This flooring uses a synthetic resin as a thin foundation foundation layer with a wood veneer decorative surface. In U.S. Pat No. 5,437,934 they disclose a Coated Cement Board Tile. While the cement board tile disclosed suffers from the serious setback that thickness calibration and edge processing is difficult and expensive, the former tile uses a high content of expensive synthetic resin and is particularly not suited for thicker panels due to economic and environmental reasons. Messner, U.S Pat No. 3,231,457 includes wood flooring in which a backing made from waste rubber is used as a foundation layer with a wood veneer surface. Elmendorf, U.S Pat No. 3,287,203 describes a plywood subfloor onto which is placed a tile having a wood fiber hardboard foundation, a natural wood layer and a vinyl resin coating. Hao et al., U.S Pat Application Publication No. US 2002 / 0142135 discloses a thermoplastic plank onto which is glued a laminate. Ill Hong Min., U.S Pat Application Publication No. US2003 / 0024637 discloses an abrasion resistant laminate formed on a polymeric substrate. PROPOSED TECHNICAL SOLUTION I propose a technical solution mentioned below, since none of known floor tile or panel methods provide the unique combination of using a. Materials such as stone, cement tile, sand polymer concrete, ceramic & reinforced cellulose based panel foundation layers, with; b. A continuous high tensile strength encapsulation which reinforces the foundation layer, renders it water and vapour proof permits a cost effective process for precise calibration of the thickness of the panel and facilitates the easy and accurate profiling of the edges to produce an interlocking system between the panels with; c. Decorative surfaces like wood, laminate, leather, metal and inlay. Further, none of the known floor tile or panel methods provide the unique combination of using thermally stable materials such as ceramic, cement tiles and stone with heat insulating materials like wood in the same panel with a water resistant encapsulation interface which can be sanded, calibrated and machined cost-effectively. DETAILED DESCRIPTION OF THE DRAWINGS For a more complete understanding of the invention, reference is hereby made to the drawings, in which: FIG 1 illustrates one preferred embodiment of the invention. Here the cross section shows a cellulose based reinforced encapsulated composite panel with profiled edges, which is one embodiment of this invention. The foundation layer shown in this figure is made of a plurality of cellulose-based panels 11 but could also be made of one or more cellulose based panels. The foundation layer is reinforced with fiber meshes between the cellulose-based panels depicted by the dotted lines in the figure. If only one cellulose based panel is used as a foundation layer, then the fiber mesh is provided on one or both sides of that panel. The encapsulation as described later in this invention is marked as 7. The decorative layer chosen fi-om the group consisting of wood, laminate, leather, metal and inlay is marked as 8. The abrasion resistant protective coating is marked as 9. The under panel protective coating is marked 12 and the plastic or fiber mesh on the bottom is marked 13. This fiber mesh 13 is in an encapsulated form made of a thermosetting resin with suitable filler so that it protects the underside of the panel and provides flexural strength, FIG la and FIG lb illustrate the general process for manufacture of the preferred embodiment of this invention. FIG la illustrates the methods for producing the foundation layer as applicable to the preferred embodiments of this inventioa The foundation layer can be produced fi-om ceramic tiles, cement tiles or stone tiles or with sand polymer concrete tiles or using cellulose based panels. When ceramic tiles; cement tiles or stone tiles are used, one or more of them can be used as the foundation layer. When sand polymer concrete tiles are used, the general method of producing these sand polymer concrete tiles is outlined in FIG la. When cellulose based panels chosen from fiberboard, plywood, LVL or hardboard is used to produce the foundation layer, the general method for producing such a foundation layer is also illustrated in FIG la. FIG lb illustrates the ensuing processes to be carried out on the selected foundation layer. The chosen foundation layer is reinforced and encapsulated and allowed to cure. The reinforced and encapsulated foundation layer is then calibrated and the chosen decorative layer bonded on to it. The decorative layer is then encapsulated and an abrasion resistant costing applied on it, followed by machining of the edge profile. For the purpose of reinforcement and encapsulation, a suitable mold of required size and shape is to be fabricated. In the subsequent figures viz. FIG 2 to FIG 17, the Foundation Layers produced using ceramic tiles, stone tiles, cement tiles, sand polymer concrete tiles are marked as 10, while the foundation Layers produced using cellulosed based panels are marked as 11. It should be noted that irrespective of the type of foundation layer being used, the ensuing processes of encapsulation and reinforcement, calibration, bonding of decorative layer, encapsulation of decorative layer and application of abrasion resistant coating and machining of edge profiles remain the same for all preferred embodiments of this invention. In the preferred embodiments of this invention which use one of ceramic tiles, stone tiles, cement tiles or sand polymer concrete tiles, the encapsulation on the edges of the foundation layer provides the convenience of easily machinable edges. In the case of preferred embodiments of this invention which use cellulose based panels for producing the foundation layer, the encapulsation provides the dual advantage of an easily machinable edge as also a water and vapour resistant protection for the foundation layer. FIG.2 shows the build up of the layered structure of the reinforced ceUulose based foundation layer. Cellulose based panels chosen from one of hardboard, fiber board, plywood and Laminated Veneer Lumber (LVL) are marked as 1. The resin mixture is marked as 2 and the glass fiber mats as 3. The foundation layer produced using cellulose based panels as shown in this drawing is marked as 11 in the subsequent drawings. FIG.3 and FIG.4 shows the cross section of a reinforced sand polymer concrete foundation layer. The polymer mortar as described later is marked as 4 and the glass fiber mats as 3. The foundation layer produced using sand polymer concrete as illustrated in this drawing is marked as 10 in the subsequent drawings. FIG.5 shows the cross section of a reinforced cement tile foundation layer. The cement mortar as described later is marked as 5 while the galvanized iron mesh or fiber mat being used is marked as 6. One embodiment of the foundation layer produced using cement as illustrated in this drawing is marked as 10 in the subsequent drawings FIG.6 shows the cross section of a reinforced and encapsulated foundation layer. In this drawing, the foundation layer 10 used is made from ceramic tiles or cement tiles or stone tiles or sand polymer concrete tiles. The encapsulation as described later in this invention is marked as 7. In the preferred embodiments of this invention which use one of ceramic tiles, cement tiles, sand polymer concrete tile or natural stone tiles as foundation layers, the encapsulation is put on the face and the four edges of the foundation layer. FIG.7 shows the cross section of a reinforced encapsulated foundation layer with a decorative layer adhered to it. In this drawing, the foundation layer 10 used is made from ceramic tiles or cement tiles or stone tiles or sand polymer concrete tiles. The encapsulation as described later in this invention is marked as 7, The decorative layer chosen from the group consisting of wood, laminate, leather, metal and inlay is marked as 8. The chosen adhesive used to bond the decorative layer with the calibrated, reinforced and encapsulated foundation layer is marked as 14. FIG.8 shows the cross section of a reinforced and encapsulated cellulose based panel foundation layer. In this drawing, the foundation layer 11 used is made from cellulose based panels. The encapsulation as described later in this invention is marked as 7. In the preferred embodiments of this invention which use reinforced cellulose based panels 11 as foundation layers, the encapsulation 7 is put on all the four edges. FIG.9 shows the cross section of a reinforced and encapsulated cellulose based panel foundation layer with a decorative layer adhered to it. In this drawing, the foundation layer 11 used is made from cellulose based panels. The encapsulation as described later in this invention is marked as 7. The decorative layer chosen from the group consisting of wood, laminate, leather, metal and inlay is marked as 8. The chosen adhesive used to bond the decorative layer with the calibrated, reinforced and encapsulated foundation layer is marked as 14. FIG. 10 shows the cross section of a reinforced and encapsulated cellulose based panel foundation layer with a stratified decorative layer adhered to it. In this drawing, the foundation layer 11 used is made from cellulose based panels. The encapsulation as described later in this invention is marked as 7. The decorative layer chosen from the group consisting of wood, laminate, leather, metal and inlay is marked as 8. The chosen adhesive used to bond the decorative layer with the calibrated, reinforced and encapsulated foundation layer is marked as 14. FIG. 11 illustrates the cross section of a reinforced encapsulated composite panel with profiled edges, which is one preferred embodiment of this invention. In this drawing, the foundation layer 10 used is made from ceramic tiles or cement tiles or stone tiles or sand polymer concrete tiles. The encapsulation as described later in this invention is marked as 7. The decorative layer chosen from the group consisting of wood, laminate, leather, metal and inlay is marked as 8. The abrasion resistant protective coating is marked as 9. FIG.12 illustrates the cross section of a reinforced encapsulated composite panel with profiled edges and an encapsulated decorative layer, which is one preferred embodiment of this invention. In this drawing, the foundation layer 10 used is made from ceramic tiles or cement tiles or stone tiles or sand polymer concrete tiles. The encapsulation as described later in this invention is marked as 7. The decorative layer chosen from the group consisting of wood, laminate, leather, metal and inlay is marked as 8. The abrasion resistant protective coating is marked as 9. FIG. 13 illustrates the cross section of a cellulose based reinforced encapsulated composite panel with profiled edges, which is one preferred embodiment of this invention. In this drawing, the foundation layer 11 used is made from cellulose based panels. The encapsulation as described later in this invention is marked as 7. The decorative layer chosen from the group consisting of wood, laminate, leather, metal and inlay is marked as 8. The underpanel protective coating is marked 12 and the plastic or fiber mesh glued on to facilitate installation is marked 13. The chosen adhesive used to bond the decorative layer with the calibrated, reinforced and encapsulated foundation layer is marked as 14. FIG.14 illustrates the cross section of a reinforced encapsulated cellulose based composite panel with a stratified decorative layer and tongue and groove edges, which is one preferred embodiment of this invention. In this drawing, the foundation layer 11 used is made from cellulose based panels. The encapsulation as described later in this invention is marked as 7. The decorative layer chosen from the group consisting of wood, laminate, leather, metal and inlay is marked as 8. The chosen adhesive used to bond the decorative layer with the calibrated, reinforced and encapsulated foundation layer is marked as 14. FIG.15 illustrates the cross section of a reinforced encapsulated composite panel with tapered profile edges and a stratified decorative layer, which is one preferred embodiment of this invention. In this drawing, the foundation layer 10 used is made from ceramic tiles or cement tiles or stone tiles or sand polymer concrete tiles. The encapsulation as described later in this invention is marked as 7. The decorative layer chosen from the group consisting of wood, laminate, leather, metal and inlay is marked as 8. The abrasion resistant protective coating is marked as 9. FIG. 16 shows the bottom view of a preferred embodiment of this invention in which a plurality of tiles are stacked and encapsulated together to form a foundation layer. In this drawing, the foundation layer 10 used is made from ceramic tiles or cement tiles or stone tiles or sand polymer concrete tiles. The encapsulation as described later in this invention is marked as 7. FIG. 17 shows the top view of a reinforced encapsulated composite panel with a decorative layer consisting of wood, metal, leather and inlay, which is one preferred embodiment of this invention. The decorative layer of wood is marked as 15, decorative layer of leather as 16, decorative layer of metal as 17 and decorative layer of inlay as 18. DETAILED DESCRIPTION OF THE INVENTION The present invention comprises reinforced encapsulated composited panel and method for making the same. Reinforced encapsulated comprisite panel is durable, stable and vapour resistant panel ideally suited for wall cladding and floor covering applications. The preferred embodiments in the invention described herein are not intended to limit the scope of this invention, as it is well known to those skilled in the art. The products of the invention are best illustrated by FIG 1. which not only depicts one preferred embodiment but also represents the general structure of the products produced with this invention. In FIG 1, thefoundation layer 11 shown is one made of a plurality of reinforced cellulose based panels, although it coukl be made of one or more ceramic tiles, stone tiles, cement tiles, polymer concrete tiles or cellulose based panels in other embodiments. The foundation layers are inevitably reinforced so as to build tensile strength (MOE) and flexural strength (MOR) , The reinforcement is done using a resin matrix, which necessarily consists of fiber, meshes or chopped fiber strands. When cellulose based panels such as plywood, hardboard, LVL and fiberboard are used as the foundation layer, they have to be reinforced so as to provide thermo hygroscopic stability. When ceramic tiles, sand polymer concrete tiles, cement tiles or stone tiles are used as foundation layers, they have to be reinforced so as to improve their modulus of rupture (MOR) properties and breaking strength during drop tests. The term ceran:uc tiles used is a laminate, the laminate itself comes with an abrasion resistant coating. The encapsulation 7 is then edge profiled so as to form a panel interlock mechanism. FIG.la & FIG.lb illustrate the general process for manufacture of the preferred embodiment of this invention. The reinforced encapsulated composite panel consist of 5 layers in three-dimensional space. The stratum, which provides structural support and integrity to the product, is the foundation layer. In the preferred embodiment of this invention, the foundation layer is selected from the group consisting of sand polymer concrete tiles, natural stone tiles, ceramic tiles, cement tiles and reinforced cellulose based panel. In the subsequent figures viz. FIG 2 to FIG 17, the Foundation Layers produced using ceramic tiles, stone tiles, cement tiles, sand polymer concrete tiles are marked as 10, while the Foundation Layers produced using cellulosed based panels are marked as 11. It should be noted that irrespective of the type of foundation layer being used, the ensuing processes of encapsulation and reinforcement, calibration, bonding of decorative layer, encapsulation of decorative layer and application of abrasion resistant coating and machining of edge profiles remain the same for all preferred embodiments of this invention. Cellulose based panels of thickness 2 to 25 mm can be used although 3mm to 5 mm thick panels are preferred. Sheets of the selected cellulose based panels are sanded preferably with Grit 60 Aluminium Oxide sandpaper in a wide belt sander. A resin mixture is prepared from about 20% to 60% by weight of unsaturated polyester resin, 39% to 80% by weight of filler and 1% to 2% by weight of methyl ethyl ketone peroxide catalyst. The preferred unsaturated polyester resins are Mechster sold by Mechemco Industries or Norpol sold by Reichhold Chemicals Inc or similar. The preferred unsaturated polyester resins should have a Tensile Strength (filled) of more than 30 MPa, Flexural Strength (filled) of more than 55 MPa, Barcol Hardness (filled) of more than 50 and a Heat Deflection Temperature of more than 85 C. Any other thermo set or thermoplastic resin can be used as long as it cures to a solid that can be worked on and is moisture resistant. Other additives such as dispersing agents, air release agents and inhibitors are added in a conventional manner. In another embodiment of this invention, sand polymer concrete tiles are used as foundation layer . Sand polymer concrete tiles can be cast in thick nesses as low as 5 mm. However, the thickness of the tile has to be increased while casting large format tiles. For example, for al200 x 600 mm tile, the thickness would have to be at least 6 mm in order to maintain enough rigidity and breaking strength. In the preferred embodiment, a homogeneous mixture of sand, imsaturated polyester resin. Methyl Ethyl Ketone In another preferred embodiment of the invention ceramic tiles are used as the foundation layer 10 as shown in FIG.6 and FIG.7. Ceramic tiles are manufactured commercially by compressing clay and firing the bisques at high temperatures. They are extremely stable and water resistant. When large format ceramic tiles are not available, small format ceramic tiles can be arranged as an array. In one preferred embodiment of this invention, an array of small format ceramic tiles are placed together and encapsulated in order to produce a large format reinforced encapsulated foundation layer. A bottom view of this embodiment is illustrated in FIG. 16. While unglazed ceramic tiles are preferred, glazed ceramic tiles with rough surface finish on the glazing can also be used as foundation In the preferred embodiments of this invention which use one of ceramic tiles, cement tiles, sand polymer concrete tile or natural stone tiles as foundation layers, the encapsulation is put on the face and the four edges of the foundation layer. The encapsulation caps the foundation layer 10 as shown in FIG.6 and reinforces it. In the preferred embodiments of this invention which use reinforced cellulose based panels 11 as foundation layers, the encapsulation 7 is put on all the four edges as shown in FIG.8. The encapsulation thus forms a continuous waterproof reinforcing band around the foundation layer with no joints or breaks. 30 MPa, Flexural Strength (filled) of more than 55 MPa, Barcol Hardness (filled) of more than 50 and a Heat Deflection Temperature of more than 85 C. Any other thermoset or thermoplastic resin can be used as long as it cures to a solid than can be worked on and is moisture resistant. Other additives such as dispersing agents, air release agents and inhibitors are added in a conventional manner. Cold pressing is preferred in this invention in order to maximize the stability of the panels. While hot pressing at temperatures of 75C or less is also possible, hot pressing requires the use of balancing layers and also increases the probability of cupping or doming of the finished panels. The inventive steps as detailed herein provide an effective means of combining materials, which are chemically, physically and mechanically different from one another. When combined together though, the end products are very stable, aesthetically pleasing and novel. SUMMARY OF THE INVENTION A feature of the present invention is to provide dimensionally stable water and vapour resistant reinforced encapsulated composite panels, which are not susceptible to damage by moisture. Another feature of this invention is to provide a panel that is economically feasible and easy to install. Another feature of this invention is that it uses one of stone, ceramic, cement, sand polymer concrete or cellulose foundation layers with a decorative surface chosen from or a combination of wood, and leather while permitting easy calibration, edge profiling and facilitating a panel interlocking system. Another feature of this invention is the it provides panels with waterproof edges, which are dimensionally precise, and those, which can be installed with minimal gaps between panels so as to maximize visual appeal. Yet another feature of this invention is that it provides panels with a lock profile on the waterproof edges such that they can be locked closely with one another and also be laid as floating installations i.e. without adhering them to the sub-floor. Another feature of this invention is to provide innovative ceramic tile panels that bear structural similarity to glazed ceramic tiles so that they can be installed simultaneously so as to create novel wall and flooring designs. Also a feature of this inventk)n is to permit a wide range of installation methods i.e. floating installation, tile glue method, cement mortar method or combinations of these methods on a wide range of surfaces including those with existing floors. Yet another feature of this invention is that moisture resistant wooden flooring panels, which can be installed alongside stone and ceramic tiles using the same installation method, can be produced. Another feature of this invention is that since the panels can be installed with minimal gaps between them, it permits use in areas like kitchens where hygiene is of prime importance. Yet another feature of this invention is that wood and wooden veneer panels, which can be used in moisture-laden areas like bathrooms can be produced. A very important feature of this invention is that it enables the combination of moisture resistant thermally stable materials like ceramic with insulating materials like wood. This combination demonstrates exceptional performance in applications where under floor heating is instaDed. The thermally stable encapsulated ceramic foundation layer protects the upper wooden decorative and insulating layer from large thermal gradients rendering stability and minimal movement to the flooring installation. cure for 5-7 days with frequent watering to allow full cure. After curing, the tiles are allowed to stabilize for 4-5 days in a dry area. After the tiles have stabilized, they are encapsulated on the sides and face as described earlier in the case of panels described in the first embodiment. Further processing is also similar to the panels described in the first embodiment. In yet another embodiment of this invention, the foundation layer is a sand polymer concrete tile. Sand polymer concrete tiles are cast on molds by mixing sand, unsaturated polyester resin, catalyst and filler material with glass fibre mat used as reinforcement. The tiles are allowed to cure overnight and encapsulated on the sides and face. Further processing is similar to that described for the panels in the first embodiment. installed alongside stone and ceramic tiles. The same product with an abrasion resistant wear layer is ideal for use as flooring panels. With a wooden decorative layer of thickness between 0.6 mm and 25 mm, and an abrasion resistant wear layer, these panels would be a superior alternative to engineered wood floors. COMMERCIAL VIABILITY There is now an ever-increasing demand from consumers for innovative floor and wall coverings, which are aesthetically pleasing while being dimensionally stable and moisture resistant. Consumers are also becoming increasingly conscious of the environment and are also demanding more environment-fiiendly products all over the world. Reinforced encapsulated composite panel is durable, stable and vapour resistant panel ideally suited for wall cladding and floor covering applications. The use of a plurality of decorative layer combinations such as wood with metal inlays and vice versa, wood with leather, wood and metal with ahalone inlays, pearl finish inlays, resin inlays and such, shall enhance its marketability. Products described in these embodiments can find use even in extreme service environments such as spas, saunas and swimming pool areas. I CLAIM: 1. A reinforced encapsulated composite panel consisting of a foundation layer selected from the group consisting of ceramic tiles, sand polymer concrete tiles, cement tiles or natural stone tiles; a high tensile strength reinforcement and encapsulation layer made of a thermosetting resin mixture and; a decorative layer selected from the group consisting of wood, laminate, leather, metal and inlay. 2. A reinforced encapsulated composite panel as claimed in claim 1 in which the foundation layer is ceramic tiles of thickness 5 mm - 15 mm, 3. A reinforced encapsulated composite panel as claimed in claim 1 in which the foundation layer is sand polymer concrete tiles of thickness 5 mm - 15 mm. 4. A reinforced encapsulated composite panel as claimed in claim 1 in which the foundation layer is cement tiles of thickness 5 mm to 25 mm. 5. A reinforced encapsulated composite panel as claimed in claim lin which the foundation layer is natural stone of thickness 5 mm to 25 mm. 6. A reinforced encapsulated composite panel as claimed in claim 1 in which the thermosetting resin mixture essentially contains, 20% - 60% by weight of an unsaturated polyester resin and 39% - 80% by weight of a filler . 7. A reinforced encapsulated composite panel as claimed in claim 1 which contains an encapsulation layer of thickness 0.6 mm to 12 mm on the face of the foundation layer. 8. A reinforced encapsulated composite panel as claimed in claim 1 which contains an encapsulation of width 0.6 mm to 100 mm on the edges of the foundation layer. 9. A reinforced encapsulated composite panel as claimed in claim 1 which contains an encapsulation of thickness 0.6 nmi to 25 mm on the face and around the edges of the decorative layer, the said encapsulation being made of a transparent thermosetting resin. 10. A reinforced encapsulated composite panel as claimed in claim 1 which contains a decorative layer of wood of thickness 0.3 mm to 25 mm coated with a protective layer selected from the group consisting of a scratch and abrasion resistant coating and an oil based coating. 11. A reinforced encapsulated composite panel as claimed in claim 1 which contains a decorative layer of laminate of thickness 0.3 mm to 2.5 mm. A reinforced encapsulated composite panel as claimed in claim 1 or as claimed in claim 8, which consists of an encapsulation, made of a thermosetting resin matrix, which is shaped on all four edges with profiles so as to form a panel interlock mechanism. , A reinforced encapsulated composite panel as claimed in claim 1 or as claimed in claim 10, which consists of an encapsulation made of a thermosetting resin matrix which is shaped on all four edges with profiles to form a panel interlock mechanism and which contains a decorative layer of wood of thickness 0.3 mm to 25 mm made of one or more layers of wood. . A method of manufacturing a reinforced encapsulated composite panel, the method comprising the steps of: providing a foundation layer selected from one of ceramic tiles, sand polymer concrete tiles, cement tiles and stone tiles; forming a high tensile strength reinforcing and encapsulating layer made of a thermosetting resin mixture on the foundation layer ; calibrating the reinforced and encapsulated foundation layer ; adhering a decorative layer selected from the group consisting of wood, laminate, leather, metal and inlay on the reinforced and encapsulated foundation layer with a water resistant adhesive selected from the group consisting of isocyanate crosslinked polyvinyl acetate, polyester, epoxy and polyurethane; providing a scratch and abrasion resistant protective coating on the decorative layer; forming a profile on the encapsulated edges of the panel. A method of manufacturing a reinforced encapsulated composite panel as claimed in claim 14, the method comprising a step of encapsulating the decorative layer on all the sides with a transparent thermosetting resin mixture. A reinforced encapsulated composite panel consisting of foundation layer made up of a plurality of cellulose based panels selected from the group consisting of hardboard, fiberboard, plywood and laminated veneer lumber, a reinforcement containing one or more glass fiber mats and a thermosetting resin mixture, all of which are assembled and pressed together to form the said foundation layer; a high tensile strength reinforcement and encapsulation layer made of a thermosetting resin mixture and a decorative layer selected from the group consisting of wood, laminate, leather, metal and inlay. A method of manufacturing a reinforced encapsulated composite panel the method comprising the steps of: providing two or more layers of cellulose based panels selected from the group consisting of hardboard, fiberboard, plywood and laminated veneer lumber; providing one or more layers of glass fiber mat; providing a homogeneous resin mixture consisting of an unsaturated polyester resin, a filler and an appropriate amount of catalyst; sanding the cellulose based panels in a wide belt sander; coating the cellulose based panels with the resin mixture at a spread rate of 2.0 kg/sqm to 6 kg/sq.m; assembling the cellulose based reinforced foundation layer by alternating a plurality of resin coated cellulose based panels with the glass fiber mats; pressing the said assembly in a pressing device at a pressure of 0.50 kg /cm2 to 5 kg/cm2 to obtain a reinforced cellulose based foundation layer ; forming a high tensile strength encapsulating layer made of a thermosetting resin mixture on the foundation layer; calibrating the reinforced and encapsulated foundation layer; adhering a decorative layer selected from the group consisting of wood, laminate, leather, metal and inlay on the reinforced and encapsulated foundation layer with a water resistant adhesive selected from the group consisting of isocyanate crosslinked polyvinyl acetate, polyurethane, epoxy and polyester; providing a scratch and abrasion resistant protective coating on the decorative layer and forming a profile on the ensapsulated edges of the panel. A reinforced encapsulated composite panel as claimed in claim 16 in which the Thermosetting resin mixture essentially contains, 20% - 60% by weight of an unsaturated polyester resin and 39% - 80% by weight of filler. A reinforced encapsulated composite panel as claimed in claim 16 in which the cellulose based panel is a hardboard of density more than 1000 kg/m3 and thickness 2 mm - 20 mm. A reinforced encapsulated composite panel as claimed in claim 16 in which the cellulose based panel is a fibreboard of density more than 800 kg/m3 and of thickness 2 mm to 25 mm. A reinforced encapsulated composite panel as claimed in claim 16 in which the cellulose based panel is plywood of thickness 2 mm - 25 mm. A reinforced encapsulated composite panel as claimed in claim 16 in which the cellulose based panel is laminated veneer lumber of thickness 2 mm - 25 mm. A reinforced encapsulated composite panel as claimed in claim 16 in which each of the glass fiber mat layers is of thickness 0.15 mm to 1.5 mm. A reinforced encapsulated composite panel as claimed in claim 16 which contains an encapsulation of width 0.5 mm to 100 mm on the edges of the foundation layer. A reinforced encapsulated composite panel as claimed in claim 16 which contains an encapsulation of thickness 0.6 mm to 25 mm on the face and around the edges of the decorative layer, the said encapsulation being made of a transparent thermosetting resin. A reinforced encapsulated composite panel as claimed in claim 16 which contains a decorative layer of wood of thickness 0.3 mm to 25 mm coated with a protective layer selected from the group consisting of a scratch and abrasion resistant coating and an oil based coating. A reinforced encapsulated composite panel as claimed in claim 16 which contains a decorative layer of laminate of thickness 0.3 mm to 2.5 mm. A reinforced encapsulated composite panel as claimed in claim 16 which contains a decorative layer of wood of thickness 0.3 mm to 25 mm which is made up by gluing a plurality of wood layers and coated with a protective layer selected from the group consisting of an abrasion resistant coating and an oil based coating; A reinforced encapsulated composite panel as claimed in claim 16 or claim 24 which consists of an encapsulation made of a resin matrix comprising of an unsaturated polyester resin, filler and reinforcement and the said encapsulation shaped on all four edges with profiles so as to form a panel interlock mechanism. A method of manufacturing a reinforced encapsulated composite panel as claimed in claim 17, the method comprising the additional step of encapsulating the decorative layer on all the sides with a transparent thermosetting resin mixture.

Documents:

069-che-2004-abstract.pdf

069-che-2004-claims filed.pdf

069-che-2004-claims granted.pdf

069-che-2004-correspondnece-others.pdf

069-che-2004-correspondnece-po.pdf

069-che-2004-description(complete) filed.pdf

069-che-2004-description(complete) granted.pdf

069-che-2004-drawings.pdf

069-che-2004-form 1.pdf

069-che-2004-form 19.pdf

069-che-2004-form 26.pdf

069-che-2004-form 3.pdf

069-che-2004-pct.pdf