Lignocellulose Panel Core and Outer Layers for Strength
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Solution Overview
Problem
Existing lignocellulosic compression molding materials and honeycomb panels face limitations in mechanical properties such as flexural strength and transverse tension, and exhibit reduced screw pull-out resistance and challenging edging processes due to their composition and structure.
Innovation Solution
Development of new lignocellulosic materials with a core and two outer layers, where the core contains treated cellulose, natural fibers, or synthetic fibers, and the outer layers consist of lignocellulose-containing particles, binders, and additives, with specific weight percentages and processing methods to enhance mechanical properties and ease of handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If honeycomb structure is used in the middle layer, then lightweight property is achieved, but screw pull-out resistance is significantly reduced
Solution Approach 1:
The panel is divided into three distinct layers: a solid core layer providing structural strength and screw holding capability, and two outer honeycomb layers providing lightweight properties. This segmentation allows each layer to fulfill its specific function without compromising the other.
Solution Approach 2:
Different regions of the panel have different structures optimized for their specific functions: the core layer has a solid, dense structure for strength and screw anchoring, while the outer layers have a honeycomb structure for weight reduction and surface quality.
2Weight of moving object
If honeycomb structure is used in the middle layer, then lightweight property is achieved, but edging process becomes difficult and requires special machines
Solution Approach 1:
By separating the honeycomb structure to only the outer layers and keeping the core layer solid, the panel combines the advantages of honeycomb (lightweight) with the manufacturing advantages of solid material (easy edging).
Solution Approach 2:
The edging-relevant outer surfaces are provided with a honeycomb structure for weight reduction, while the core layer remains solid to facilitate standard edging operations. This local differentiation of structure optimizes both weight and manufacturability.
3Ease of manufacture
If compression molding materials are made from wood chips or fibers, then production is simplified, but mechanical properties such as flexural strength and transverse tension are insufficient
Solution Approach 1:
The panel uses a composite structure combining wood-based particles in the core layer with a plastic foam honeycomb structure in the outer layers. This composite approach allows the wood particles to provide structural integrity and strength, while the plastic honeycomb provides lightweight properties and surface quality.
Solution Approach 2:
Different material compositions are used in different layers: the core layer uses wood particles for strength and structural properties, while the outer layers use plastic foam for lightweight characteristics and surface quality, optimizing both manufacturing and performance.
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 new materials demonstrate improved mechanical properties, including increased flexural strength and screw pull-out resistance, while simplifying edging processes, resulting in a more efficient and effective production of lightweight, yet robust, lignocellulose-based panels.
Implementation Method 1
A) 30 to 98 wt% of one or more binders selected from the group consisting of amino resin, phenol-formaldehyde resin and organic isocyanate
Implementation Method 2
the core containing treated cellulose, treated natural fibers, synthetic fibers or mixtures thereof
Data Source
AI summary
The invention relates to materials containing lignocellulose that have a core and two covering layers, containing and preferably consisting of, in said core: A) 30 to 98 wt.% of lignocellulose particles, B) 0 to 25 wt.% of expanded plastic particles with a bulk density in the range of 10 to 150 kg/m3, C) 1 to 50 wt.% of one or more binders selected from the group consisting of aminoplast resin, phenol formaldehyde resin, and organic isocyanate with at least two isocyanate groups, and D) 0 to 10 wt.% of additives, and, in said covering layers: E) 70 to 99 wt.% of lignocellulose-containing particles, fibres, or mixtures thereof, F) 1 to 30 wt.% of one or more binders selected from the group consisting of aminoplast resin, phenol formaldehyde resin and organic isocyanate with at least two isocyanate groups, and G) 0 to 10 wt.% of additives; with 2 to 30% of the lignocellulose particles A) being replaced with treated cellulose materials, treated natural fibres, synthetic fibres or mixtures thereof. The invention also relates to the production and use of same.