Wood Panel Hybrid Layer Solid Wood Chipboard
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Solution Overview
Problem
Cross-laminated timber panels are limited by the high cost and inefficient use of wood resources due to the requirement for high-quality solid wood elements, leaving only 50% of log wood mass suitable for production, while the remaining residual wood is not utilized effectively.
Innovation Solution
A wooden panel design featuring two outer visible layers of solid wood elements and at least one intermediate hybrid layer composed of both solid wood and chipboard elements, allowing for the full utilization of log wood mass and replicating the static properties of cross-laminated timber panels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If cross-laminated timber panels are produced using only solid wood boards, then the panel has high static load-bearing capacity and structural resilience, but the wood resource utilization is inefficient with only 50% of log wood mass being processed into solid wood boards
Solution Approach 1:
The patent applies composite materials by combining solid wood boards with chipboard in a hybrid layer structure. The solid wood boards provide structural strength and load-bearing capacity, while the chipboard component utilizes residual wood material that would otherwise be wasted, achieving both high strength and improved wood mass utilization (up to 80% efficiency).
Solution Approach 2:
The patent segments the panel structure into distinct functional layers: outer visible layers made of solid wood boards for aesthetic and structural purposes, and intermediate hybrid layers combining solid wood and chipboard elements for optimized resource utilization. This segmentation allows each layer to serve its specific function while collectively achieving both strength and sustainability goals.
2Reliability
If only high-quality solid wood elements are used to produce cross-laminated timber panels, then the panel achieves comparable properties to traditional cross-laminated timber, but the production cost increases due to the high price of solid wood boards
Solution Approach 1:
The patent applies local quality by using solid wood boards specifically in the outer visible layers where aesthetic appearance and structural integrity are most important, while using cost-effective chipboard in the intermediate hybrid layers where structural support is sufficient but cost reduction is prioritized. This localized material selection maintains panel reliability while significantly reducing production costs.
Solution Approach 2:
By creating a composite structure with solid wood and chipboard, the patent reduces dependence on expensive solid wood boards alone, thereby lowering production costs while maintaining acceptable panel properties through the synergistic contribution of both materials.
3Ease of manufacture
If solid wood boards are sawn from logs, then the panel structure is simple and easy to manufacture, but only about 50% of the log wood mass can be processed into solid wood boards while the remaining wood mass becomes waste
Solution Approach 1:
The patent converts the previously harmful waste product (residual wood, sawdust, wood chips) into a valuable component (chipboard) that is integrated into the panel structure. This transforms the waste stream into a resource, increasing wood mass processing efficiency from 50% to up to 80% while maintaining manufacturing simplicity through the use of standard chipboard production processes.
Solution Approach 2:
Instead of discarding residual wood material from log processing, the patent recovers and reprocesses it into chipboard elements that are incorporated into the hybrid layers of the panel structure, thereby recovering valuable wood mass that would otherwise be lost.
Data Source
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AI summary
The invention relates to improvements in the technical field of wood panels. For this purpose, a wood panel (1) with two outer visible layers (2) and at least one intermediate layer (3, 4) arranged between the visible layers (2) is proposed. At least one of the visible layers (2) consists of solid wood elements (5). At least one intermediate layer of the wood panel is a hybrid layer (3, 4) comprising at least one solid wood element (5, 7, 8) and at least one particleboard element (6).