Lamella Core Production Method for Building Panels
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Solution Overview
Problem
The production of wood lamella cores for building panels faces challenges due to the use of low-grade sawn timber boards with knots, cracks, and varying lengths, leading to material waste and inefficiency in the production process.
Innovation Solution
A method involving the arrangement of distance strips on sawn timber boards, applying pressure to straighten and bond them, and cutting the solid batch to maximize material yield, which includes calibrating the solid batch rather than individual boards to achieve straight timber, and using a combination of glues and materials like wood fibers and cross-linked polymers for enhanced bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If sawn timber boards with varying lengths and curved shapes are used directly in production, then material waste increases, but the productivity and yield of usable material decrease
Solution Approach 1:
The method applies preliminary straightening action to curved sawn timber boards before they are glued together to form the lamella core. By pre-straightening the boards using pressing equipment, the invention eliminates the need to discard curved boards, thereby reducing material waste while maintaining high productivity and yield of usable material.
2Ease of manufacture
If low-grade sawn timber boards with knots and cracks are used, then production costs decrease, but the strength and reliability of the lamella core worsen
Solution Approach 1:
The invention applies local quality control by selectively positioning and treating areas of the low-grade timber boards. By straightening and properly joining the boards in critical load-bearing positions, the method ensures that the final lamella core achieves sufficient strength and reliability even when made from lower-grade material with knots and cracks in non-critical areas.
3Manufacturing precision
If individual sawn timber boards are calibrated before assembly, then positioning precision improves, but the complexity and time of the manufacturing process increases
Solution Approach 1:
The invention merges the calibration and straightening operations into a single integrated process step. Instead of calibrating each board individually before assembly, the method combines straightening and positioning into one operation during the gluing process, thereby achieving the necessary positioning precision while reducing manufacturing process complexity and time.
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 method increases the yield of usable material for building panels by straightening curved boards and optimizing the use of substandard timber, reducing waste and improving the strength and stability of the final product.
Implementation Method 1
gluing the distance strips (14) to the first and the second sawn timber board, respectively
Data Source
Figure 1A~1E
Figure 2
Figure 3A~3D
AI summary
A method of producing a semi-product for a building panel, such as a floorboard, wherein the method includes the step of: arranging at least two distance strips (14), on a first sawn timber board; arranging a second saw timber board (15) to the distance strips (14); applying a glue; positioning of the first and the second sawn timber board and the distance strips by applying a pressure; and applying a pressure (P3) on the first and the second sawn timber board by a third and a fourth element (72,73), in a direction perpendicular to a top surface of the second sawn timber board, until the distance strips is bonded by the glue to the first and the second sawn timber board and thereby obtaining a solid batch; and cutting of said solid batch in the length direction of the first and the second timber boards.