Corrugated Zigzag Wood Core Layer for Lightweight Composite Stability
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Solution Overview
Problem
Existing multi-layer composites with loosened core layers have low homogeneity due to large cavities, leading to instability when fastened with nails or screws, and require large, high-quality veneer for production, which is inefficient and costly.
Innovation Solution
A core layer comprising zigzag-shaped wooden elements with platelet-shaped areas arranged in a zigzag pattern, where edges intersect at non-zero angles and are firmly connected, providing improved stability and reduced material requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a loosened core layer structure is used to achieve lightweight multi-layer composites, then weight is reduced and damping effect is improved, but homogeneity decreases and fastening stability deteriorates
Solution Approach 1:
The patent applies curvature by transforming flat veneer sheets into corrugated structures with wave-like profiles. The corrugations create a three-dimensional geometry that enhances mechanical interlocking between layers and provides anchoring points for fasteners, thereby improving fastening stability while maintaining the lightweight advantage of the loosened core structure.
Solution Approach 2:
The patent creates a composite structure by combining multiple corrugated veneer layers with different grain directions and orientations. The core layer consists of corrugated veneers arranged at angles to each other, forming a heterogeneous composite that achieves both lightweight properties and improved homogeneity for reliable fastening.
2Manufacturing precision
If large pieces of high-quality veneer are used to produce large-format core layers, then production quality is maintained, but material cost increases and production efficiency decreases
Solution Approach 1:
The patent segments the core layer into multiple smaller corrugated veneer pieces that can be independently produced and then assembled. This segmentation allows for more efficient production of individual components and facilitates easier handling and assembly, thereby improving overall production efficiency while maintaining quality through standardized manufacturing of each segment.
Solution Approach 2:
The patent transitions from two-dimensional flat veneer sheets to three-dimensional corrugated structures. This dimensional transformation enables the creation of large-format core layers from smaller veneer pieces by stacking and arranging corrugated elements, improving production efficiency without compromising the quality and structural integrity of the final product.
3Ease of manufacture
If flat veneer sheets are used for the core layer, then production is simple, but mechanical stability and carrying capacity are insufficient
Solution Approach 1:
The patent applies curvature by transforming flat veneer sheets into corrugated structures with wave-like profiles. This geometric transformation significantly enhances mechanical stability and carrying capacity while maintaining relatively simple production processes, as the corrugations can be formed through conventional veneer processing techniques.
Solution Approach 2:
The patent transitions from two-dimensional flat veneer to three-dimensional corrugated structures. This dimensional change adds structural complexity that improves mechanical stability and load-bearing capacity, while the corrugation formation process remains integrated into existing veneer manufacturing workflows, preserving ease of manufacture.
Data Source
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AI summary
Core layer which is suitable for a multi-layer composite which has at least one cover layer and a core layer, the cover layer being arranged in such a way that it at least partially covers the core layer and is firmly connected to it, the core layer having elements made of wood which are platelet-shaped have areas which are arranged in a zigzag shape, with a platelet-shaped zigzag area of an element with an adjacent platelet-shaped zag area of the element forming a common edge between them, such that the zigzag-shaped wooden element is formed, wherein zig-zag shaped elements are arranged in the core layer such that two such edges of two different elements intersect at a non-zero angle and the two elements are fixedly connected to each other at the point of intersection. In one embodiment, a zigzag-shaped wooden element can be glued to a planar wooden element in such a way that a zigzag-shaped wooden element is surrounded by two planar wooden elements in a sandwich-like manner; or two zigzag-shaped wooden elements surround a flat wooden element like a sandwich.