Engineered Wood Planks Using Lap Splice Joints
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Solution Overview
Problem
Existing engineered wood plank manufacturing methods face challenges in producing longer planks efficiently, especially with limited availability of wood in desired lengths, and require stronger bonding to withstand bending during the manufacturing process, which is not effectively addressed by traditional methods.
Innovation Solution
The use of shorter sections of wood joined together with a specific lap splice joint configuration, comprising a first lap joint section extending perpendicularly, a second lap joint section extending parallel, and a third lap joint section, to form longer lamella layer planks that are then adhered to a backing material, enhancing bonding strength and wear resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional bonding methods are used to join shorter wood sections, then manufacturing simplicity is maintained, but bonding strength is insufficient to withstand bending during the manufacturing process
Solution Approach 1:
The joint is divided into three distinct lap joint sections with specific length ratios, creating segmented bonding zones that distribute stress and enhance overall bonding strength while maintaining manufacturability
Solution Approach 2:
The invention specifies precise parameter relationships (length ratios between sections) to optimize bonding strength, transforming the joint from a simple connection to a engineered structure with controlled mechanical properties
2Productivity
If longer wood sections are used to create longer planks, then productivity is improved, but availability of suitable wood material decreases
Solution Approach 1:
The plank is segmented into multiple shorter wood sections joined by lap splice joints, enabling production of long planks from readily available shorter wood material while maintaining manufacturing efficiency
Solution Approach 2:
Multiple shorter wood sections are merged through adhesive bonding in lap joint configurations to create longer continuous planks, combining the advantages of available material with desired plank length
3Quantity of substance
If multiple shorter wood sections are joined together, then availability of material is improved, but bonding strength must be enhanced to prevent failure during bending
Solution Approach 1:
The bonding system is segmented into three lap joint sections with specific length relationships, creating multiple bonding zones that distribute bending stresses and enhance reliability
Solution Approach 2:
Different sections of the joint have different length characteristics optimized for their specific functions, with the second section being the longest to provide primary bonding strength under bending loads
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 enables the efficient production of longer engineered wood planks with improved bonding and wear characteristics, allowing for quicker installation and utilizing more widely available, cost-effective shorter wood sections, while maintaining the appearance of solid wood flooring.
Implementation Method 1
the first lamella layer section is adhered to the second lamella layer section by a first lamella lap splice joint
Data Source
AI summary
An engineered wood plank made using a unique lamella layer. The lamella layer has a number of lamella layer sections joined together by lap splice joints which allow the lamella layer to be pressure adhered onto a backing material without breaking, and wear in a manner similar to known engineered hardwood flooring.