Laminated Wood Element with Intermediate Insulation Layer
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Solution Overview
Problem
Existing layer composite elements, such as laminated wood, face challenges in achieving improved insulation against heat, wind, and noise, and are difficult to manufacture due to issues like shifting wood pieces during drilling and lack of full-surface adhesion, leading to gaps and cracks.
Innovation Solution
Incorporating an intermediate layer, such as a natural fiber fleece or woven fabric, with optional adhesive and strategically placed dowels, along with trough-like depressions in the wood layers to enhance insulation and mechanical stability, and using a combination of mechanical and adhesive connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If exclusively mechanical fixing is used to join wood layers, then chemical binders are avoided and disposal is simplified, but the position of wood pieces cannot be fixed until connecting means are introduced, causing shifting during drilling and creating gaps and openings
Solution Approach 1:
An adhesive layer is applied to the wood layers before the mechanical connecting means (dowels) are introduced. This preliminary adhesive application fixes the position of wood pieces during the drilling process, preventing shifting and gap formation, while the final structural integrity is achieved through the combination of adhesive and mechanical connectors.
2Adaptability or versatility
If wood pieces are allowed to shift freely during preparation, then manufacturing flexibility is maintained, but gaps and openings arise between pieces that form continuous channels reducing insulation
Solution Approach 1:
An intermediate layer consisting of adhesive material is introduced between the wood layers. This intermediary substance fills gaps and prevents continuous channel formation between layers, thereby maintaining insulation performance while still allowing manufacturing flexibility during the assembly process.
3Device complexity
If no full-surface adhesive layer is used, then manufacturing simplicity is maintained, but cracks and openings arise in individual layers depending on joining accuracy and shrinkage
Solution Approach 1:
The connection system combines two different materials: adhesive (chemical bonding) and mechanical connectors (physical bonding). This composite approach compensates for the limitations of each individual method - the adhesive provides continuous coverage that prevents cracks from forming, while the mechanical connectors provide precise positioning and structural strength.
4Productivity
If known laminated wood elements are used, then production is established, but they fail to meet stringent requirements for insulation against heat, wind, and noise
Solution Approach 1:
An intermediate layer of adhesive material is introduced between the wood layers to seal gaps and prevent continuous channels. This intermediary layer significantly improves insulation performance against heat, wind, and noise while maintaining compatibility with existing manufacturing processes for laminated wood elements.
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 significantly improves insulation values, simplifies manufacturing by preventing shifting and cracking, and enhances mechanical stability, while being ecologically friendly and cost-effective.
Implementation Method 1
at least one adhesive layer (21) is present which penetrates the intermediate layer (8) over the whole area or over part of the area
Implementation Method 2
The intermediate layer improves the insulation in terms of windproofness, sound, odor and heat transmission
Implementation Method 3
The intermediate layer improves the insulation in terms of windproofness, sound, odor and heat transmission
Implementation Method 4
The layer composite element consists of a total of five different layers (3-7), in particular of board-like timbers (24) which are arranged directly next to one another and held together by dowels (9)
Data Source
Figure 1~2
Figure 3~4
Figure 5~7
AI summary
The method involves compressing plies in area of a joint against a work surface (20), and drilling a hole in the joint, where the plies are laid out on the work surface. Plugs (9) are inserted in the hole and the pressing of the plies are sustained while drilling and the placing the plugs. The plugs are mechanically squeezed in diameter and subjected with water before the insertion into the hole. An independent claim is also included for an apparatus for manufacturing a laminated unit.