Zig-Zag Wood Core Layer for Lightweight Load-Bearing Panels
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Solution Overview
Problem
Multilayer composites with broken-up core layers exhibit low homogeneity due to large cavities, leading to instability when fastened with nails or screws, and require large, high-quality veneer pieces for production, which limits their load-bearing capacity and weight efficiency.
Innovation Solution
A core layer with wood elements arranged in zig-zag-shaped form, where zig and zag regions form a common edge and cross at a non-zero angle, are fixedly connected, and covered by a surface layer, enhancing mechanical stability and load-bearing capacity while maintaining low weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a broken-up core layer structure is used, then weight is reduced and damping action is improved, but homogeneity decreases and fastening stability deteriorates
Solution Approach 1:
The core layer is divided into multiple individual wood elements (veneers, strips, or particles) arranged in a broken-up configuration. These segmented elements create cavities that reduce weight and provide damping, while still maintaining structural integrity through their distributed arrangement and fixed connections to surface layers.
Solution Approach 2:
The wood elements are arranged to create local variations in density and structure throughout the core layer. This local quality variation optimizes both weight reduction in cavity regions and structural support in regions with higher element concentration, while the fixed connections ensure fastening stability is maintained at critical locations.
2Strength
If large veneer pieces are used for core layer production, then load-bearing capacity is improved, but material cost and production complexity increase
Solution Approach 1:
Instead of using large continuous veneer pieces, the core layer is constructed from multiple smaller wood elements. These elements can be more easily manufactured, handled, and arranged, reducing production complexity while maintaining load-bearing capacity through their collective structural arrangement and fixed connections.
Solution Approach 2:
The core layer functions as a composite structure combining multiple wood elements with different orientations and arrangements. This composite approach distributes mechanical loads across numerous elements rather than relying on a single large piece, achieving comparable or superior load-bearing capacity with simpler manufacturing.
3Weight of moving object
If a broken-up core layer with large cavities is used, then weight is reduced, but homogeneity decreases
Solution Approach 1:
The core layer incorporates local variations in element distribution and cavity sizes, creating a non-uniform structure that optimizes weight reduction while maintaining sufficient homogeneity for structural performance. The fixed connections to surface layers ensure that critical regions maintain adequate density and composition stability.
Data Source
AI summary
A core layer suitable for a multilayer composite including at least one surface layer and one core layer, the surface layer arranged to at least partially cover the core layer and be fixedly connected thereto, wherein the core layer has elements composed of wood, which elements have plate-like regions arranged in zig-zag-shaped fashion, wherein a plate-like zig region of an element with an adjoining plate-like zag region of the element form a common edge between them, in such a way that the wood element of zig-zag-shaped form is formed, wherein elements of zig-zag-shaped form are arranged in the core layer such that two such edges of two different elements cross one another at a non-zero angle, and wherein the two elements are fixedly connected to one another at the crossing point. In one embodiment, a wood element of zig-zag-shaped form may be adhesively bonded to a planar wood element.