Undulated Wood Fiber Core Layer for Lightweight Panel Stability
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Solution Overview
Problem
Current lightweight building materials with loosened core layers face challenges in achieving high stability and homogeneity due to large cavities, which affect their mechanical properties and load-bearing capacity.
Innovation Solution
A multi-layer composite wave-shaped lightweight sheet element is developed, featuring interconnected wood fibers with a core layer that consists of overlaid waves, enhancing the rigidity and stability by creating a stiffening effect while maintaining low weight, achieved through specific wave shapes and orientations in the core layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a loose core layer structure is used to reduce weight, then the weight of the multilayer composite is reduced, but the homogeneity and mechanical stability deteriorate due to large cavities
Solution Approach 1:
The patent applies curved, wave-like structures to the core layer elements instead of flat planar structures. The undulated elements with curved surfaces create a more homogeneous distribution of material throughout the core layer, eliminating large cavities while maintaining the lightweight advantage. The curvature provides structural rigidity and improves load distribution across the core layer.
Solution Approach 2:
The patent uses composite construction within the core layer by combining multiple undulated elements with different orientations and configurations. This creates a heterogeneous composite structure at the micro-level that achieves macro-level homogeneity, improving mechanical stability while maintaining low weight through the optimized arrangement of different element types.
2Weight of moving object
If a loose core layer structure is used to reduce weight, then the weight of the multilayer composite is reduced, but the load-bearing capacity deteriorates
Solution Approach 1:
The undulated elements with curved surfaces provide superior load-bearing capacity compared to flat elements. The curved geometry naturally distributes applied loads more evenly across the element structure, preventing stress concentration points. This allows the core layer to support higher loads while maintaining a lightweight construction with reduced material usage.
Solution Approach 2:
The patent transitions from two-dimensional flat core layer elements to three-dimensional undulated elements with complex spatial configurations. This dimensional enhancement adds structural complexity that improves load-bearing capacity in multiple directions simultaneously, allowing the lightweight core layer to resist forces from various orientations without requiring increased material density.
3Ease of manufacture
If flat planar elements are used in the core layer, then the manufacturing is simple, but the rigidity and stability are insufficient
Solution Approach 1:
The undulated elements are designed with curved surfaces that can be formed through standardized manufacturing processes such as thermal forming or molding. These curvature-based structures achieve high rigidity and stability inherent to the geometry itself, eliminating the need for additional bracing or complex reinforcement while maintaining manufacturing efficiency through process standardization.
Solution Approach 2:
The patent optimizes specific geometric parameters of the undulated elements, such as wave amplitude, wavelength, and curvature radius, to achieve the desired rigidity-stability balance. By carefully controlling these dimensional parameters within specific ranges, the elements gain enhanced mechanical properties while remaining compatible with existing manufacturing capabilities and processes.
Data Source
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AI summary
Lightweight panel element, wherein the element has the shape of a spatially extending first wave, wherein the top of the element has at least one wave crest and the bottom of the element has at least one wave trough, wherein the first wave propagates transversely or radially, and wherein the at least one wave crest and the at least one wave trough are in the form of a second wave, and wherein the lightweight panel element has or consists of wood fibers or wood chips connected together or of wood fibers and wood chips connected together.