Core layer having wood elements, in particular wood elements having a corrugated structure
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Solution Overview
Problem
Multilayer composites with broken-up core layers exhibit low homogeneity due to large cavities, leading to instability when fastened with nails or screws, and require large, high-quality veneer pieces for production, which limits their load-bearing capacity and weight efficiency.
Innovation Solution
A core layer with wood elements arranged in zig-zag-shaped form, where zig and zag regions form a common edge and cross at a non-zero angle, are fixedly connected, enhancing mechanical stability and load-bearing capacity while maintaining low weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a broken-up core layer structure is used, then weight is reduced, but homogeneity deteriorates and stability against fastening deteriorates
Solution Approach 1:
The core layer is segmented into multiple thin veneer layers (3-7 layers) with alternating fiber directions, creating a broken-up structure that reduces weight while maintaining homogeneity. Each layer is relatively thin (0.2-0.8mm) and the layers are arranged in a staggered pattern, preventing large continuous cavities while still achieving weight reduction compared to solid core layers.
Solution Approach 2:
Adjacent veneer layers are arranged with their fiber directions running in substantially opposite directions (e.g., 0°/90° or 45°/-45°), creating an asymmetric alternating pattern. This asymmetric arrangement of fiber orientations enhances structural stability and prevents the formation of large cavities, thereby improving reliability against fastening while maintaining the lightweight broken-up structure.
2Ease of manufacture
If large veneer pieces are used to produce core layers, then production difficulty is reduced, but load-bearing capacity and weight efficiency deteriorate
Solution Approach 1:
Instead of using large single veneer pieces, the core layer is constructed from multiple thin veneer layers (3-7 layers) with alternating fiber directions. This segmentation allows the use of smaller, more manageable veneer pieces that are easier to produce and handle, while the layered structure itself provides enhanced load-bearing capacity through the alternating fiber orientations that distribute stresses more effectively.
Solution Approach 2:
The core layer employs a composite structure consisting of multiple veneer layers with alternating fiber directions (e.g., 0°/90° or 45°/-45°). This composite arrangement combines the ease of manufacturing individual thin layers with the superior load-bearing capacity of the multi-directional fiber structure, achieving both manufacturability and strength.
3Weight of moving object
If a broken-up core layer with large cavities is used, then weight is reduced, but homogeneity deteriorates
Solution Approach 1:
The core layer is divided into multiple thin veneer layers (3-7 layers) with alternating fiber directions, creating a fine-grained broken-up structure rather than large cavities. This segmentation achieves weight reduction through the layered construction while maintaining homogeneity by preventing the formation of large void spaces, as each layer is closely bonded to its neighbors.
Solution Approach 2:
Each veneer layer in the broken-up structure possesses specific local qualities with alternating fiber directions (e.g., longitudinal vs. transverse). This local variation in fiber orientation creates a heterogeneous microstructure that prevents large cavity formation while maintaining overall homogeneity at the macro level, achieving both weight reduction and compositional stability.
Data Source
AI summary
A core layer suitable for a multilayer composite including at least one surface layer and one core layer, the surface layer arranged to at least partially cover the core layer and be fixedly connected thereto, wherein the core layer has elements composed of wood, which elements have plate-like regions arranged in zig-zag-shaped fashion, wherein a plate-like zig region of an element with an adjoining plate-like zag region of the element form a common edge between them, in such a way that the wood element of zig-zag-shaped form is formed, wherein elements of zig-zag-shaped form are arranged in the core layer such that two such edges of two different elements cross one another at a non-zero angle, and wherein the two elements are fixedly connected to one another at the crossing point. In one embodiment, a wood element of zig-zag-shaped form may be adhesively bonded to a planar wood element.