Method and apparatus for stationary production of layer material

Abstract

The invention relates to a method and an apparatus for stationary production of layer material and can be used for example in the wood industry for producing products from laminated wood, but also generally for producing products on the basis of other materials such as fibre materials or plastics. The method for producing layer material from lamellae (L1, L2, ... Ln) is based on providing at least one material layer with an adhesive (K), then applying a surface, provided with the adhesive (K), of the one material layer to at least one further material layer and connecting the material layers to one another by applying a pressing force, wherein pressure roller pairs (RP1, RP2, ... RPn) which are adjustable in different dimensions in a computer-controlled manner are used to exert a controlled pressure on the material layers to be connected. The apparatus for producing layer material from lamellae (L1, L2, ... Ln) comprises a drive device, at least one or in each case one actuator (A) for generating a pressing force, and pressure roller pairs (RP1, RP2, ... RPn) which are arranged in pairs, can be moved in a plurality of degrees of freedom, can be set in a computer-controlled manner and are operatively connected to the actuator (A) via pressing rollers (AR1, AR2, ... ARn) for generating the pressing force.

Description

[0001] Method and apparatus for the stationary production of layered material

[0002] The invention relates to a method and a device for the stationary production of layered material and is applicable, for example, in the wood industry for the production of products made of laminated wood, but also generally for the production of products based on other materials such as fiber materials or plastics.

[0003] Introduction

[0004] Laminated timber, also known as glulam (glued laminated timber), allows for the production of timber beams in dimensions that exceed the limits of naturally grown tree trunks. By gluing together individual layers of laminated timber, timber profiles of virtually any length, width, and thickness can be manufactured. Furthermore, defects and weaknesses in the wood, such as knots, cracks, or unfavorable grain patterns, are bridged in one layer by the layers above and below. This results in beams with a higher load-bearing capacity than solid wood itself.

[0005] State of the art

[0006] From DE 102015206 130 B3 a process for the production of laminated wood is known, wherein at least one layer of wood is provided with an adhesive, then an adhesive-provided surface of one layer of wood is applied to at least one further layer of wood and the layers of wood are joined together by applying a pressing force.

[0007] The system provides that the pressing force is applied to the wood layers via pressing elements of a joining machine, while one of the wood layers is positioned and the joining machine with drive and guide devices moves automatically along a path defined by the positioned wood layer.

[0008] A key element of this solution is the wood layer that defines the track in the form of a template or mother lamella.

[0009] This state-of-the-art solution describes a hand-held device for manufacturing large components, such as 40-meter-long bridge girders in one piece, or wooden ring beams for buildings with a diameter of, for example, 16 meters. A shape is defined by a so-called mother lamella, a first, form-giving lamella made of wood or metal, etc. This lamella is then coated with further lamellae, so that layer by layer a glulam beam grows to the required thickness.

[0010] In short, the state of the art, also known as LEIMKÄFER 1.0, is a tool for carpenters.

[0011] In the Glue Beetle 1.0, the mother lamella is the shaping element. The Glue Beetle I.0 is a passive roller unit that follows the mold, pressing down the top, glued layer (lamella). The device has, for example, two pairs of rollers that generate the necessary gluing pressure and move the Glue Beetle forward along a prepared, precisely measured mold lamella. The rollers are passively movable and adapt to the predetermined shape they follow.

[0012] A heating element integrated into the unit stimulates the curing of the thermo-activated adhesive. Once the glue-applying roller unit leaves the bonding area, the newly applied lamella is sufficiently bonded to the underlying lamella.

[0013] The object of the present invention is to provide a method and a device for producing layered materials with which a wide variety of products with different shapes can be produced flexibly and efficiently without the use of templates or mold or mother lamellae.

[0014] Disclosure of the invention

[0015] The subject of the present invention, also referred to in abbreviated form as LEIMKÄFER 2.0, IS A TOOL FOR CARPENTERS.

[0016] The Leimkäfer 2.0 does not have a mother lamella for shaping. If a bend is required, additional pairs of forming pressure rollers are used alongside the transport and pressure rollers, with each pair of pressure rollers consisting of a pressure roller and a counter-pressure roller. It is also possible that no separate transport rollers exist, but rather that at least one pair of pressure rollers handles the feed.

[0017] The pairs of pressure rollers are able to change their span in such a way as to compensate for dimensional tolerances.

[0018] Furthermore, the span between the pairs of pressure rollers can be significantly varied while maintaining constant pressure. This is advantageous when bonding inserted molded parts and lamellae with tapered or thickening thicknesses. The driven transport rollers allow two lamellae to be bonded continuously. The use of the additional or alternatively shaped pressure roller pairs allows the lamellae to bend during the bonding process. This is therefore not a plastic deformation of a component, but rather the positioning of multiple components through bonding. The practicality of this device depends heavily on the process speed, which in turn is contingent upon the adhesive curing process being ultra-fast.

[0019] If the workpieces are small and handy, they can be conveniently processed on stationary, large machines.

[0020] For example, a bicycle frame is to be made from plywood. Depending on the design, this is a specially shaped, closed frame. It can also consist of right and left frame sections that are then joined to form a complete frame. The rear fork can also be constructed in this way.

[0021] According to the invention, the roller position of the pressure roller pairs is extended to an actively variable position. This allows the shape of the lamellae to be bonded to be precisely defined at the moment of bonding. The specific springback of the material is determined and taken into account. Through appropriate control, for example, a CNC control, the height and the horizontal and vertical angles of inclination of the pressure roller pairs relative to each other are changed. This results in a correspondingly curved and coiled shape.

[0022] If the machine is programmed accordingly, identical shapes can be easily produced repeatedly and then further processed. By gradually building up the final material thickness, prefabricated (pre-milled, cast, or printed) components made of wood, metal, plastic, etc., can be inserted at suitable points and enclosed by subsequent layers.

[0023] For example, a stable, very lightweight bicycle frame can be manufactured as a closed frame form, in which reinforcements for the bottom bracket, seat post and other structurally necessary attachment points are inserted.

[0024] To allow for design-related changes in the thickness of the layered material elements, prefabricated inserts or inclusions can be glued in for thickening or reinforcement. These inclusions are thus enclosed by the fibers (lamellae) running above and below them, much like branches in a tree. For this purpose, the pressure roller pairs are not only adjustable in position and angle, but the passage between the rollers can also be changed while maintaining constant pressure (e.g., using pneumatic cylinders).

[0025] Glued laminated timber is currently manufactured exclusively from straight-edged lamellae.

[0026] Straight lamellae can, for example, be transformed into a hollow body with a circular cross-section by bending the two ends of the straight lamella towards each other and subsequently connecting them.

[0027] The method presented here also allows for the relatively simple implementation of curved lamellae. Using curved lamellae further increases the possible variety of shapes.

[0028] Curved lamellae can, for example, be transformed into a hollow body with a truncated cone shape by bending the two ends of the curved lamella towards each other and subsequently joining them together.

[0029] The subject matter of the present invention therefore relates to a method for producing layered material from lamellae, wherein at least one material layer is provided with an adhesive, then an adhesive-provided surface of one material layer is applied to at least one further material layer and the material layers are joined together by applying a pressing force, wherein a controlled pressure is exerted on the material layers to be joined via pairs of pressure rollers which are designed to be adjustable in various dimensions by computer control.

[0030] This offers the advantage that the production of the layered material can take place on stationary machines and that a wide variety of product shapes can be produced.

[0031] In addition to pressure loading, vibrations, ultrasound or high-frequency treatment and heat input can complement the manufacturing process.

[0032] In a preferred embodiment of the present invention, it is provided that a thermally activatable adhesive is used and that this is activated by a heating device.

[0033] In a further preferred embodiment of the present invention, an adhesive that can be activated by contact, in other words under pressure, is used, or other activation mechanisms are provided, such as activation by changing the ambient atmosphere or by light such as UV. Furthermore, a further object of the invention is a device for producing layered material from lamellae, comprising a drive unit, at least one actuator for generating a contact force, and pairs of pressure rollers arranged in multiple degrees of freedom, which are operatively connected to the actuator via pressure rollers for generating the contact force, wherein the pressure roller pairs are adjustable by computer control.

[0034] Whether the pressure roller pairs are arranged separately or whether the pressure elements also serve as the drive unit must be decided on a case-by-case basis for the specific technical application. Both applications are possible.

[0035] As with the Glue Beetle 1.0, depending on the application of the pre-glued elements, the processing of lamellae made from various materials is possible, such as fiberglass, carbon fiber, synthetic fibers, or fibers from natural materials, as well as woven, knitted, or woven fabrics made from these fibers, and also metal mesh, sheet metal, wood-based material, or plastic lamellae. Depending on the type of materials used, the appropriate type of bonding or joining method (e.g., friction welding), or the appropriate type of adhesive, must be determined and modified.

[0036] Brief description of the characters

[0037] The invention is explained in more detail below with reference to exemplary embodiments illustrated at least partially in the figures. The figures show:

[0038] Figurl is an arrangement of the printing roller pairs for the production of products with a straight arrangement of the lamellae.

[0039] Figure 2 shows another view of the arrangement of the printing roller pairs for the production of products with a straight arrangement of the lamellae.

[0040] Figure 3 shows an arrangement of the printing roller pairs for the production of products with arc-shaped lamellae.

[0041] Figure 4 shows another view of the arrangement of the printing roller pairs for the production of products with arc-shaped lamellae. Figure 5 shows an arrangement of the printing roller pairs for the production of products with multiple arc-shaped lamellae.

[0042] Figure 6 shows an arrangement of the printing roller pairs for the production of products with a coiled arc shape of the lamellae.

[0043] Figure 7 shows a support with conical lamellae.

[0044] Figure 8 shows a support with sharpened lamellae.

[0045] Figure 9 shows part of a bicycle frame with elements for the bottom bracket.

[0046] Figure 10 shows a bicycle frame with several functional elements

[0047] Figure 11 shows a straight lamella bent into a cylindrical shape.

[0048] Figure 12 shows a curved lamella bent into a truncated cone shape.

[0049] Detailed description of the invention

[0050] As can be seen in Fig. 1, a total of three pairs of pressure rollers RP1, RP2, and RP3 are arranged when two lamellae L1 and L2 are joined. Each pair of pressure rollers RP1, RP2, and RP3 has a pressure roller AR1, AR2, and AR3, respectively, and a counter-pressure roller GR1, GR2, and GR3. In this embodiment, the pairs of pressure rollers RP1, RP2, and RP3 are controlled such that the joined lamellae L1 and L2 maintain a straight shape. At least one pair of pressure rollers RP1, RP2, or RP3 provides the feed.

[0051] Between the two interconnected lamellae L1 and L2 is a layer of adhesive KS. The adhesive KS was heated before joining using an induction heating device IH.

[0052] The heating process activates the adhesive KS, and the pressing takes place in the direction away from the induction heating device IH.

[0053] Fig. 2 shows the same situation as Fig. 1, but from a different perspective. Here, the heating device for heating the adhesive KS between the lamellae L1 and L2 is also shown in detail; in this embodiment, it is designed as an induction heating device IH. Thus, Figs. 1 and 2 illustrate an embodiment in which the three pairs of pressure rollers RP1, RP2, and RP3 are adjusted to ensure a straight shape for the connected lamellae L1 and L2.

[0054] Figures 3 and 4 show the production of layered material in arc form.

[0055] For this purpose, the individual pairs of rollers RP1, RP2 and RP3 are designed to be height-adjustable, rotatable and tiltable, and are computer-controlled to create a curved shape of the connected lamellae L1 and L2.

[0056] Fig. 5 now shows an embodiment in which the three pairs of pressure rollers RP1, RP2 and RP3 are adjusted several times so that a multiply and differently curved shape of the connected lamellae L1 and L2 is realized.

[0057] Finally, Fig. 6 shows an embodiment in which the three pairs of pressure rollers RP1, RP2 and RP3 are adjusted so that, in addition to the multiple and differently curved shape of the connected lamellae L1 and L2, a coiled shape is realized.

[0058] The pressure roller pairs RP1, RP2 and RP3 are designed in such a way that they can be adjusted in height by computer control and rotated or swivelled horizontally and vertically.

[0059] Fig. 7 shows an embodiment of a carrier with conical lamellae L1 to Ln. Such carriers are intended for special applications, for example for special shapes with movable pressure rollers.

[0060] The pressure roller pairs RP1, RP2 and RP3 of the stationary “glue beetle” adhesive device are able to change their span so that dimensional material tolerances can be compensated for.

[0061] Furthermore, the span between the pressure rollers can be varied considerably while maintaining constant pressure. This is advantageous when bonding molded parts, as shown in Fig. 9, as well as when dealing with tapered or thickening lamella thicknesses, as shown in Fig. 7.

[0062] In this way, even pre-treated wooden elements with discontinuous thicknesses or varying thicknesses can be covered with lamellae, as shown in Fig. 8. This makes it possible to conceal the wooden elements.

[0063] Since this finished, pre-processed wooden element has a fixed shape, a mobile glue beetle, i.e., the Glue Beetle 1.0, can be used here, which requires a mother lamella or mold lamella, i.e., a predefined shape. The beam with sharpened lamellae Li shown in Fig. 8 also finds application in construction, for example in bridging structures.

[0064] Fig. 9 shows a specific embodiment where elements T for receiving a bottom bracket are integrated into a bicycle frame made of curved lamellae L1 to Ln. The integration is achieved by bonding the element T.

[0065] Fig. 10 shows a complete frame for a bicycle, in which various elements T, R and S are incorporated.

[0066] Fig. 11 shows a forming variant in which straight lamellae LG, for example, are formed into a cylindrical hollow body HZ, i.e. a hollow body with a circular cross-section, by bending the two ends of the straight lamella LG towards each other and subsequently joining them together.

[0067] Fig. 12 shows how curved lamellae LK, for example, are transformed into a hollow body HKS with a truncated cone shape by bending the two ends of the curved lamella LK towards each other and subsequently joining them together.

[0068] The invention is not limited to the embodiments shown here. Rather, it is possible to realize further embodiments of the invention by combining and varying the features shown, without departing from the scope of the invention.

Claims

Patent claims 1. Method for producing layered material from lamellae (L1 , L2 ... Ln), wherein at least one material layer is provided with an adhesive (K), then an adhesive-provided surface of one material layer is applied to at least one further material layer and the material layers are joined together by applying a pressing force, characterized in that a controlled pressure is exerted on the material layers to be joined via pairs of pressure rollers (RP1 , RP2 ... RPn), which are designed to be adjustable in various dimensions by computer control.

2. Method according to claim 1, characterized in that in each pair of pressure rollers (RP1 , RP2 and RP 3) a pressure roller (AR1 , AR2 and AR3) interacts with a counter-pressure roller (GR1 , GR2 and GR3).

3. Method according to claim 1, characterized in that the pairs of pressure rollers (RP1 , RP2 ... RPn) are adjustable in height and in the horizontal and vertical angle of inclination.

4. Method according to claim 1, characterized in that the production of the layer material takes place on stationary machines and a wide variety of shapes of the products to be manufactured are possible.

5. Method according to claim 1, characterized in that the shape of the lamellae to be bonded (L1 , L2 ... Ln) is precisely defined at the moment of their bonding and the specific springback of the material is determined and taken into account.

6. Method according to claim 1, characterized in that the adhesive (K) is a thermally activatable adhesive (K) and this is activated via an induction heating device (IH).

7. Method according to claim 1, characterized in that the adhesive (K) is an adhesive (K) that can be activated by contact under pressure, or activation is carried out by changing an ambient atmosphere, or curing is supported by the action of ultrasound, UV light or laser, or by high-frequency radiation.

8. Method according to at least one of the preceding claims, characterized in that prefabricated molded parts made of wood, metal, plastic, etc. are inserted at suitable locations by gradually building up the final material thickness and are enclosed by the following layers.

9. Device for producing layered material from lamellae (L1 , L2,... Ln), comprising a drive device, at least one actuator (A) for generating a contact force, pairs of pressure rollers (RP1.RP2 ... RPn) arranged in several degrees of freedom, which are operatively connected to the actuator (A) via pressure rollers (AR1 , AR2 ... ARn) for generating the contact force, wherein the pressure roller pairs (RP1.RP2 ... RPn) are adjustable by computer control.

10. Device according to claim 9, characterized in that each pair of pressure rollers (RP1 , RP2 and RP3) has a pressure roller (AR1 , AR2 and AR3) and a counter-pressure roller (GR1 , GR2 and GR3).

11. Device according to claim 9, characterized in that the pressure roller pairs (RP1 , RP2 ... RPn) are designed to be adjustable in height and in the horizontal and vertical angle of inclination.

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