Wood Flake Panel Forming System with Rotatable Distributors
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Solution Overview
Problem
Existing wooden flake panel production systems, like OSB, are not suitable for applications requiring aesthetic appearance and are inefficient in material usage, leading to high production costs and environmental impact due to the gaps between flakes and the need for extensive outer coating.
Innovation Solution
A system that produces Light Strand Board (LSB) panels with short-flake outer layers and long-flake inner layers, allowing for low-density panels comparable to multiply panels, and enabling easy switching between OSB and LSB production using a dual forming machine setup with rotatable distributor elements to separate and arrange flakes effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If long flakes are used in outer layers to ensure structural strength, then mechanical properties are improved, but aesthetic appearance deteriorates due to larger gaps between flakes
Solution Approach 1:
The patent applies different flake length qualities to different layers: long flakes in inner layers for structural strength, short flakes in outer layers for aesthetic appearance. This local differentiation resolves the contradiction by optimizing each layer's flake length according to its specific functional requirements.
Solution Approach 2:
The panel is segmented into multiple layers with different flake characteristics. The outer layers use short flakes while inner layers use long flakes, creating a segmented structure that simultaneously achieves both aesthetic appearance and mechanical strength.
2Shape
If short flakes are used in outer layers to improve aesthetic appearance, then surface quality is improved, but structural strength deteriorates
Solution Approach 1:
Short flakes are locally applied only to outer layers where aesthetic appearance is critical, while long flakes are used in inner layers where structural strength is required. This localized quality assignment resolves the contradiction without compromising overall panel strength.
Solution Approach 2:
The panel structure is segmented into outer and inner layers with different flake lengths. This segmentation allows short flakes to improve surface quality in outer layers while long flakes maintain structural strength in inner layers.
3Shape
If extensive coating material is applied to cover gaps between flakes, then aesthetic appearance is improved, but production cost increases
Solution Approach 1:
The patent performs preliminary action by using short flakes in outer layers during panel formation, which inherently creates a smoother surface with fewer gaps. This preliminary structural optimization reduces the need for extensive subsequent coating, thereby lowering production costs.
Solution Approach 2:
The invention extracts the root cause of surface imperfections (large gaps from long flakes) by replacing long flakes with short flakes in outer layers. This eliminates the need for extensive coating material to cover gaps, directly reducing production costs.
4Shape
If extensive coating material is applied to improve aesthetic appearance, then surface quality is improved, but panel density increases
Solution Approach 1:
By preliminarily configuring outer layers with short flakes, the patent creates a naturally smoother surface that requires minimal coating. This preliminary action prevents the need for dense coating layers, thereby maintaining low panel density.
Solution Approach 2:
The invention extracts the requirement for dense coating by using short flakes in outer layers, which inherently provide better surface quality. This eliminates the need to apply heavy coating material, thus preventing density increase.
5Shape
If extensive coating material is applied to cover gaps, then aesthetic appearance is improved, but environmental impact increases
Solution Approach 1:
The patent uses short flakes in outer layers as a preliminary measure to create a smoother surface, reducing the need for extensive coating applications. This preliminary structural optimization decreases the consumption of coating materials and associated environmental impacts.
Solution Approach 2:
By extracting the root cause of surface imperfections (using long flakes in outer layers), the invention eliminates the need for extensive coating material application, thereby reducing environmental impact from coating production and application processes.
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 system produces panels with improved aesthetic suitability, reduced material usage, lower production costs, and decreased environmental impact by allowing for efficient production of low-density LSB panels while maintaining mechanical properties comparable to OSB, and facilitates quick switching between OSB and LSB production.
Implementation Method 1
allow the fall of the short flakes (6) on the support plane (2) and the dragging of the long flakes (7) above the distributor elements (5)
Implementation Method 2
dragging the long flakes causing them to advance along a direction defined by their direction of rotation
Data Source
Figure 1
Figure 2
AI summary
A system (1) for the production of panels, particularly for the production of panels made of wood flakes, comprising: at least a support plane (2) movable along a direction (4) of forward movement; at least a first and a second forming machine (3a, 3b) arranged in succession to one another along the direction (4) of forward movement above the support plane (2) and each comprising at least a first set (5a) of distributor elements (5) rotatable around respective axes, the distributor elements (5) being able to select a flow of wooden material (6, 7) comprising short flakes (6) and long flakes (7) so as to allow the fall of the short flakes (6) on the support plane (2) and the dragging of the long flakes (7); where the first forming machine (3a) and the second forming machine (3b) comprise at least a second set (5b) of distributor elements (5) operable independently of the relative first set (5a) and where the distributor elements (5) of the first set (5a) are operable in rotation in both ways.