Segmented Wood Components for Wall Elements with Cavities
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Solution Overview
Problem
The existing methods for producing cross-laminated timber wall elements are complex and result in significant wood waste, with a high cost due to the need for precise layering and gluing of boards, which complicates the process and increases material usage.
Innovation Solution
A method involving the intelligent separation of a starting part into components with varying thicknesses using cutting processes like broaching or sawing, allowing for the creation of plate-shaped elements that can be assembled to form wall elements with cavities, which can be used individually or layered to achieve desired structural and thermal properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If boards are pre-profiled to create cavities for thermal benefits, then thermal insulation performance is improved, but the manufacturing process becomes more complex and wood waste increases
Solution Approach 1:
The starting part is segmented into multiple components with different thicknesses through cutting processes. This segmentation creates cavities between components of varying thicknesses, achieving thermal insulation without requiring complex pre-profiling of entire boards. The segmentation principle transforms a complex pre-profiling operation into simpler cutting and assembly steps.
Solution Approach 2:
Components are designed with locally varying thicknesses rather than uniform thickness throughout. This local quality variation creates cavities in specific regions where thermal insulation is needed, while maintaining structural integrity in other areas. The local quality principle allows cavities to be formed through simple thickness variation rather than complex cavity carving.
2Strength
If multiple layers of boards are precisely layered and glued to form wall elements, then structural strength is improved, but manufacturing cost and material usage increase
Solution Approach 1:
The starting part is divided into multiple components that can be assembled into wall elements. This segmentation allows for more efficient material utilization compared to traditional multi-layer board construction, as components are cut to precise requirements from a single starting part, reducing excess material usage while maintaining structural integrity through the layered assembly of segmented components.
Solution Approach 2:
Components are designed with asymmetric thickness variations rather than uniform symmetric layers. This asymmetry allows optimization of material distribution - thicker sections where structural strength is needed and thinner sections where less strength is required - thereby reducing overall material usage while maintaining necessary structural performance.
3Loss of substance
If components of varying thicknesses are assembled to form wall elements with cavities, then material usage is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The starting part is pre-cut into components with specific thickness variations before assembly. This preliminary action of cutting components to precise thicknesses from the starting part allows for reduced material waste, as the cutting process can be optimized to minimize offcuts. The precision requirements are managed through systematic pre-cutting rather than post-assembly adjustments.
Data Source
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AI summary
In order to produce the end products, an initial part is divided into at least two components such that the latter have different thicknesses over the width thereof. The initial part is divided intelligently such that the end product is produced from the components resulting from the dividing process or is formed therefrom. The components resulting after the dividing process can already be the end products in the form of strips. However, it is also possible to subsequently assemble the components resulting after the dividing process to form the end product, for example a wall element.