Multi-layer Wood-Metal Material Deformability
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Solution Overview
Problem
Existing multi-layer materials with metal enhancing layers are expensive and prone to breakage or cracking when bent to form complex shapes, as they lack deformability and suffer from adherence issues over time, especially in areas of high curvature.
Innovation Solution
Incorporating at least one layer of metal material between wood-based sheets, with optional additional metal layers and varying sheet thickness to enhance elasticity and deformability, allowing for the creation of objects with curvilinear forms without compromising structural integrity or aesthetic appeal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metal enhancing layers are used in multi-layer materials, then aesthetic appearance and durability are improved, but cost increases significantly and deformability decreases
Solution Approach 1:
The patent changes the thickness parameter of internal wood-based sheets progressively from one end to the other, creating zones of different thickness. This allows the material to be shaped into complex forms while maintaining structural integrity, and enables cost-effective production by using varying amounts of material rather than requiring expensive metal enhancing layers throughout.
Solution Approach 2:
The patent creates a composite multi-layer material combining wood-based sheets with metal layers, where the metal layers are strategically positioned and the wood-based sheets have varying thickness. This composite structure achieves both durability and deformability at lower cost compared to traditional metal-enhancing approaches.
2Ease of manufacture
If constant thickness is maintained in multi-layer materials, then manufacturing simplicity is preserved, but deformability and ability to form complex shapes is reduced
Solution Approach 1:
The patent applies local quality by creating zones of different thickness within the multi-layer material. Internal wood-based sheets have progressive thickness reduction from one end to the other, allowing specific areas to be more flexible for shaping while other areas maintain structural strength. This enables complex curvilinear forms to be achieved during manufacturing.
Solution Approach 2:
The patent segments the multi-layer material into multiple wood-based sheets with varying thicknesses arranged in sequence. This segmentation allows each layer to contribute differently to the overall deformability, with thinner sections enabling greater flexibility and thicker sections providing structural support, thus facilitating complex shape formation.
3Shape
If excessive curvature is imposed on multi-layer materials, then complex shapes can be achieved, but cracks and breakages occur in internal layers
Solution Approach 1:
The patent uses progressive thickness reduction of internal wood-based sheets from one end to the other, creating a gradient structure. This parameter change allows the material to accommodate curvature stresses more effectively, as thinner sections can bend more easily without cracking while thicker sections maintain structural integrity, enabling complex curvilinear shapes to be formed safely.
Solution Approach 2:
The patent provides beforehand cushioning by designing the thickness gradient in advance, where thinner sections are positioned to accommodate high-curvature areas. This pre-designed thickness variation acts as a cushion against stress concentration, preventing cracks and breakages in internal layers when the material is shaped into complex forms.
4Ease of manufacture
If enhancing layers are made from synthetic resins, then cost is reduced, but adherence to internal layers deteriorates over time especially in curved zones
Solution Approach 1:
The patent uses parameter changes in the thickness of internal wood-based sheets to create a gradient structure that improves adherence. The progressive thickness reduction creates better mechanical interlocking and distribution of adhesive forces, preventing detachment of enhancing layers over time, especially in curved zones, while maintaining cost-effectiveness.
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 enables the production of durable, economically viable multi-layer materials that can be easily shaped into complex forms without breaking or cracking, while maintaining a desirable appearance, by increasing elasticity and reducing the risk of adherence loss.
Implementation Method 1
by inserting at least one layer of metal material, for example a metal foil, between two wood-based sheets, it is possible to increase the overall elasticity and deformability of the multi-layer material itself, allowing to at least partly curve the multi-layer material and reducing the possibility of breakages and/or cracks
Implementation Method 2
interposing appropriate adhesive materials between adjacent wood-based sheets and between the layer of metal material and the adjacent wood-based sheets; exerting an adequate pressure on the wood-based sheets and on the layer of metal material thus associated so as to obtain their reciprocal gluing
Data Source
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AI summary
Multi-layer material comprising a plurality of wood-based sheets (14) comprising at least a layer (11, 12) of metal material interposed between two wood-based sheets (14).