Wood Wool Construction Element Density Control
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Solution Overview
Problem
Existing methods for producing wood wool construction elements result in inconsistent density throughout the thickness due to compression, and they are not easily adaptable for incorporating inlays without interrupting production.
Innovation Solution
A method involving the use of elongated wood wool fibers with specific dimensions, wetted with a hydraulic binder, and a production facility that allows for continuous production with contiguously positioned moulds, enabling uniform density and easy incorporation of inlays without interrupting the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the fresh material is compressed under its own weight during production, then the construction element achieves sufficient structural strength, but the density becomes high and non-uniform throughout the thickness
Solution Approach 1:
The production process is divided into distinct phases: first filling the mold with wood wool mixture, then adding water, and finally applying compression only after the mixture has set. This segmentation prevents premature compression that would cause non-uniform density, while still achieving sufficient structural strength through the setting process and controlled final compression.
Solution Approach 2:
The wood wool mixture is filled into the mold and allowed to set before compression is applied. This preliminary action of setting prevents the material from being compressed too early, which would cause high density and non-uniform structure. The setting process prepares the material to accept compression in a controlled manner, achieving both uniform density and structural strength.
2Productivity
If traditional production methods are used, then the construction element is produced efficiently, but inlays cannot be incorporated without interrupting production
Solution Approach 1:
Inlays are positioned in the mold before the wood wool mixture is filled. This preliminary action allows inlays to be incorporated during the normal production flow without interrupting the process. The mixture is then poured over the inlays and allowed to set, maintaining continuous production while achieving versatile inlay integration.
Solution Approach 2:
The process combines inlay placement with the standard mold-filling operation. By merging the inlay incorporation step into the existing production sequence (positioning inlays before filling), the system maintains high productivity while achieving adaptability for inlay integration without requiring separate production interruptions.
3Temperature
If elongated wood wool fibers are used with specific dimensions, then thermal insulation performance is improved, but the manufacturing process becomes more complex
Solution Approach 1:
The patent specifies particular parameter ranges for wood wool fiber length (2-5 cm) and diameter (0.2-0.5 mm) to optimize thermal insulation. By controlling these parameters within defined ranges, the process achieves improved thermal performance without excessive complexity. The parameters are optimized to balance insulation performance with manufacturability using standard equipment.
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 method achieves a more consistent and lower density throughout the thickness of the construction elements, allowing for efficient thermal insulation and easy integration of inlays without production interruptions, enhancing the structural integrity and thermal performance.
Implementation Method 1
The hydraulic binder binds to the wood wool
Implementation Method 2
The wood wool that is used in the method according to the present invention is wetted, so as to provide a good binding capacity with the hydraulic binder
Data Source
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AI summary
A method for producing a wood wool construction element. This method comprises the steps of dispersing at least a part of a mixture of wood wool and a hydraulic binder in a mold so as to obtain a layer of the mixture with a height that is less than the height of side walls of said mold. Said mixture is at least partially hardened after which a subsequent layer of mixture is provided. The thickness of a construction element may well exceed 30 cm, for example 40 cm, 50 cm or even 60 cm. Also, an element obtained with such method is described, as well as a production facility.