Balsa Core Composite Panel With Perpendicular Fiber Orientation
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Solution Overview
Problem
Existing composite panels with balsa cores and veneer wood layers lack the load-bearing capacity required for commercial vehicle construction, particularly for loading floors, walls, and roofs.
Innovation Solution
A composite panel with a balsa wood core bonded to multi-layer structural veneer plywood, where the fibers of intermediate layers are oriented perpendicular to the inner and outer layers, enhancing load-bearing capacity while maintaining lightweight properties, and optionally incorporating GRP, CFRP, or natural fiber mats for further strength and flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a balsa core with veneer wood layers is used, then the panel is lightweight, but the load-bearing capacity is insufficient
Solution Approach 1:
The patent combines balsa wood core with veneer wood layers of different fiber orientations to create a composite panel structure. This composite construction maintains the lightweight advantage of balsa wood while the multi-layer veneer structure with perpendicular fiber orientations provides enhanced load-bearing capacity in multiple directions, resolving the contradiction between light weight and high strength.
Solution Approach 2:
The patent applies veneer wood layers with specific fiber orientations at different locations within the panel structure. The inner and outer layers have fibers oriented in a first direction, while intermediate layers have fibers oriented in a second direction perpendicular to the first. This local variation in fiber orientation optimizes the panel's strength characteristics in different regions and loading directions while maintaining overall lightweight construction.
2Strength
If intermediate layers with perpendicular fiber orientation are added, then load-bearing capacity increases, but panel complexity increases
Solution Approach 1:
The patent divides the veneer structure into multiple discrete layers with different fiber orientations. The panel consists of an inner layer, one or more intermediate layers, and an outer layer, where each layer can be independently manufactured and positioned. This segmentation allows for optimized strength characteristics while maintaining manufacturing feasibility through standardized layer production and assembly processes.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution significantly increases load-bearing capacity while maintaining a lightweight structure, suitable for commercial vehicle applications, with the ability to absorb high loads and shear forces effectively.
Implementation Method 1
a balsa core (10) and building veneer plywood (11) which are bonded to one another
Data Source
Figure 1
Figure 2
AI summary
The plate has a core (10) made of balsa wood and connected with a multi-layered building veneer plywood (11). The wood comprises an inner layer closer to the core, an outer layer and an intermediate layer arranged between the inner and outer layers. The layers are made of carbon fiber-reinforced plastic fiber mats, fiber reinforced plastics or natural fiber mats. The fibers of the inner and outer layers run in a direction, and the fibers of the intermediate layer are oriented in another direction, which runs perpendicular to the former direction.