Wooden Panel Manufacturing Using Segmented Slat Layers
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Solution Overview
Problem
Current methods for producing wooden panels are complex, expensive, and inefficient, particularly in forming middle layers, which require precise cutting and gluing of slats of uniform length, leading to high material waste and labor costs, and are prone to defects causing panel instability.
Innovation Solution
A method where short slats are arranged end-to-end to form longer layers, intelligently controlled for optimal length, and glued together with their narrow sides to create blocks, allowing for the use of slats of varying lengths and tolerating minor defects, reducing waste and processing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If slats of uniform length are used and precisely cut, then manufacturing precision is improved, but material waste increases and production complexity increases
Solution Approach 1:
The method segments slats into different length categories (first slats, second slats, third slats) based on their dimensions. This segmentation allows each slat type to be utilized optimally in the panel construction, reducing the need for precise uniform cutting and minimizing wood waste while maintaining manufacturing precision through controlled classification.
Solution Approach 2:
The invention changes the parameter approach from requiring uniform slat length to accepting variable slat lengths within defined ranges. By establishing parameter ranges for different slat categories and using them in layered construction, the method achieves manufacturing precision through controlled parameter variation rather than uniformity, thereby reducing material waste.
2Manufacturing precision
If slats of uniform length are used, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The production system is segmented into multiple functional units: a classification device that sorts slats by length, a feeding mechanism that delivers different slat types to appropriate positions, and a pressing device that consolidates the layered structure. This segmentation reduces overall system complexity by dividing the uniformity maintenance task into manageable functional components rather than requiring a single complex precision-cutting system.
Solution Approach 2:
The classification device automatically sorts slats into different length categories based on their inherent dimensions, and the feeding mechanism automatically positions them in the panel construction. This self-service approach eliminates the need for complex manual measurement and cutting systems, reducing device complexity while maintaining manufacturing precision through automated classification and positioning.
3Loss of substance
If short slats are joined together, then material waste is reduced, but reliability decreases due to potential defects
Solution Approach 1:
The method applies local quality by assigning different slat types to different positions within the panel structure. First slats (longer) are placed in specific locations, second slats (medium) in others, and third slats (shorter) in remaining positions. This localized placement ensures that slat length variations and potential defects are distributed strategically, maintaining panel reliability while reducing material waste through optimal utilization of all slat types.
Solution Approach 2:
The invention creates a composite panel structure combining multiple slat types with different lengths and properties. By layering first slats, second slats, and third slats in a controlled sequence and pressing them together, the method achieves a homogeneous composite material that maintains structural reliability despite the variability in individual slat dimensions, while maximizing material utilization.
4Manufacturing precision
If manual gluing of individual sticks is performed, then manufacturing precision is improved, but loss of time increases
Solution Approach 1:
The feeding mechanism automatically positions slats in the pressing device, and the pressing device simultaneously applies pressure and facilitates glue application across multiple slats. This self-service approach eliminates manual gluing operations, reducing production time while maintaining manufacturing precision through controlled automated positioning and pressure application that ensures consistent glue distribution and bond quality.
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
This method enables cost-effective and straightforward production of wooden panels with improved material yield, allowing for the optimal use of raw wood and minimizing defects, resulting in stable and high-quality panels with reduced personnel and material costs.
Implementation Method 1
The slats are pressed together with their glued longitudinal sides to form a block
Implementation Method 2
glued together with their narrow sides to create blocks
Data Source
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AI summary
To produce wood panels, lamellae are glued on their narrow sides and pressed together in a gluing press to form a sheet of lamellae. To reliably produce wood panels in a cost-effective and simple manner, the lamellae (B) are arranged one behind the other to create longer layers (29). The lamellae (B) are intelligently joined so that the end lamellae (B) within the layer (29) are long enough not to interfere with further processing of the wood panel. The layers (29) are then joined together to form the wood panel (28). This process is used to produce wood panels (28), including core layers.