Corrugated Wooden Core Layer for Lightweight Building Boards
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Solution Overview
Problem
Conventional multi-layer composites for lightweight building boards face challenges in achieving stability at reduced density while maintaining dimensional accuracy and machinability, due to the requirement for high-quality raw materials and low pressure pressing, which leads to poor retention of hardware and impaired processing.
Innovation Solution
A core layer with wavy wooden elements arranged in an oriented manner, allowing interlocking of wave crests and troughs to form cavities, which enhances stability and processing capabilities, and can be produced using a method involving scattering and bonding of OSB strands or strand-like materials with an adhesive under controlled pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If low pressure pressing is used to produce core layer with corrugated wooden elements, then weight-to-stability ratio is improved, but dimensional accuracy and machinability deteriorate
Solution Approach 1:
The patent changes the pressing pressure parameter from high to low range, achieving improved weight-to-stability ratio while accepting reduced dimensional accuracy. This parameter optimization allows the core layer to maintain structural integrity through the corrugated element geometry rather than relying on high pressing pressure for density.
Solution Approach 2:
The patent creates local quality differences by forming cavities between corrugated wooden elements through low-pressure pressing. These localized cavity structures reduce overall density and improve weight-to-stability ratio, while the corrugated elements themselves maintain sufficient dimensional accuracy for structural applications.
2Strength
If low pressure pressing is used to produce core layer with corrugated wooden elements, then weight-to-stability ratio is improved, but hardware retention and fitting insertion capacity deteriorate
Solution Approach 1:
The patent optimizes the pressing pressure parameter to a low range, which creates a core layer structure with cavities that reduces density and improves weight-to-stability ratio. The corrugated wooden element geometry compensates for the reduced pressing pressure, maintaining sufficient structural reliability for hardware retention.
Solution Approach 2:
The patent uses composite construction with corrugated wooden elements arranged in specific patterns, creating a multi-component core layer structure. This composite approach allows the corrugated elements to provide structural reinforcement that compensates for the lower pressing pressure, maintaining hardware retention capability while reducing overall density.
3Stability of the object's composition
If high-quality starting products are used for core layer production, then cohesion of individual layers is ensured, but material cost and complexity increase
Solution Approach 1:
The patent changes the pressing pressure parameter to a low range, which reduces the quality requirements for starting materials. The low-pressure process is more tolerant of variations in raw material quality, allowing the use of lower-grade wooden elements while still achieving sufficient layer cohesion through the corrugated structure geometry.
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 achieves high strength and stability with reduced material usage, ensuring comparable stability to conventional composites at reduced density, and improves machinability, including the introduction of standardized fittings, by utilizing the interlocking structure of wavy elements.
Implementation Method 1
bonding of OSB strands or strand-like materials with an adhesive under controlled pressure
Data Source
AI summary
Core layer which is suitable for a multi-layer composite which has at least one cover layer and the core layer, wherein the cover layer is arranged such that it at least partially covers the core layer and is fixedly connected thereto, and multi-layer composite having the core layer, wherein the core layer has layers of corrugated wooden elements, wherein the corrugated wooden elements are arranged in an oriented manner in at least one layer.