Cross Laminated Strand Product Using Segmented Layer Manufacturing
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Solution Overview
Problem
Conventional engineered wood products, such as OSB, face issues with unreliable layer thickness control and poor cross-wise material properties due to differences in strand orientation deposition techniques, leading to variability in material properties and reduced performance.
Innovation Solution
A cross laminated strand product is manufactured with layers of substantially aligned wood strands bonded with an isocyanate resin, where adjacent layers are oriented perpendicularly, using pre-formed boards with controlled thickness and alignment, and glued together using PUR glue, to enhance both length-wise and cross-wise performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional OSB manufacturing processes are used with sequential strand deposition, then production efficiency is maintained, but layer thickness control becomes unreliable and material property variability increases
Solution Approach 1:
The manufacturing process is divided into separate stages: pre-forming individual layers with controlled thickness and orientation, then assembling these pre-formed layers into the final panel. This segmentation allows precise control of each layer's properties independently while maintaining production efficiency through parallel processing.
Solution Approach 2:
Layers are pre-formed with controlled thickness and strand orientation before final panel assembly. This preliminary action ensures consistent layer properties are achieved before the layers are combined, eliminating the thickness control issues that occur with sequential deposition in conventional processes.
2Adaptability or versatility
If strands are deposited with different orientations in sequential layers, then cross-wise material properties improve, but alignment quality deteriorates due to different deposition techniques
Solution Approach 1:
The panel is constructed from separate pre-formed layers, each with controlled strand orientation. This allows different layers to be optimized for different directions (length-wise and cross-wise) while maintaining high alignment quality in each layer through dedicated pre-forming processes.
Solution Approach 2:
Each layer is given specific local quality characteristics with strands oriented to optimize performance in particular directions. Outer layers have strands oriented for length-wise strength, while core layers have cross-wise orientation, with each layer's alignment optimized for its specific function.
3Reliability
If renewable plantation wood sources are used instead of old growth forests, then sustainability is improved, but wood quality consistency worsens
Solution Approach 1:
The use of strands cut from plantation wood allows segmentation of the material into small, uniform pieces. This segmentation distributes any natural variations or faults throughout the final product, preventing localized weaknesses and achieving consistent overall performance despite variations in source material.
Solution Approach 2:
The manufacturing process transforms raw plantation wood into standardized strands with controlled dimensions and properties. This parameter change from raw material to processed strands ensures consistent material characteristics regardless of natural variations in the source wood.
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
This approach results in well-defined layers with improved alignment and performance characteristics, reducing variability and increasing the cross laminated strand product's suitability for structural applications, while also providing a sustainable alternative to plywood by utilizing renewable wood sources.
Implementation Method 1
substantially aligned strands of wood bonded together with a binder including an isocyanate resin
Data Source
AI summary
A cross laminated strand product formed from a laminate of a plurality of layers, wherein each layer includes substantially aligned strands of wood bonded together with a binder including an isocyanate resin, and wherein the respective strands of adjacent layers are oriented substantially perpendicularly to one another.