Zigzag Wood Core Layer for Stable Lightweight Sandwich Panels
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing multi-layer composites with loosened core layers have low homogeneity due to large cavities, leading to instability when fastened with nails or screws, and require large, high-quality veneer for production, which limits their stability and efficiency.
Innovation Solution
A core layer with zigzag-shaped wooden elements arranged at non-zero angles and firmly connected, forming a stable and homogeneous structure that improves mechanical stability and reduces the need for large veneer pieces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a loosened core layer structure is used to achieve damping effect and lightweight properties, then weight is reduced and energy absorption is improved, but homogeneity deteriorates due to large cavities causing fastening instability
Solution Approach 1:
The patent changes the structural parameters of the core layer by introducing zigzag-shaped wooden elements with specific geometric characteristics (wave height h, wavelength λ, amplitude a) rather than using conventional loosened structures. This parameter optimization allows achieving both lightweight properties and improved homogeneity for stable fastening.
Solution Approach 2:
The patent uses composite construction by combining wooden elements with corrugated paper or fabric layers to create the core layer. This composite structure provides both the lightweight damping effect and the structural homogeneity needed for reliable fastening, resolving the contradiction between weight reduction and fastening stability.
2Strength
If large pieces of high-quality veneer are used to produce core layers, then structural integrity is improved, but material cost and production complexity increase
Solution Approach 1:
The patent divides the core layer into multiple smaller zigzag-shaped wooden elements instead of using large continuous veneer pieces. These segmented elements can be manufactured separately and then assembled, reducing production complexity while maintaining structural integrity through the interlocking zigzag configuration and adhesive bonding.
Solution Approach 2:
The patent employs curved corrugated structures (zigzag patterns) in the wooden elements rather than flat planar forms. This curvature provides structural strength and rigidity comparable to large veneer pieces, while allowing the core layer to be constructed from smaller, more manageable components that are easier to manufacture and assemble.
3Reliability
If zigzag-shaped wooden elements are firmly connected to improve homogeneity and fastening stability, then mechanical stability is enhanced, but device complexity increases
Solution Approach 1:
The patent merges multiple zigzag-shaped wooden elements into a unified core layer structure through adhesive bonding at their edges. This combining approach creates improved homogeneity and fastening stability while keeping the individual element geometry relatively simple, thus not significantly increasing overall device complexity.
Solution Approach 2:
The patent utilizes the zigzag pattern's geometric arrangement in multiple dimensions, where elements are positioned and oriented to create a three-dimensional interlocking structure. This dimensional arrangement provides structural complexity that enhances stability without requiring overly complicated individual component designs.
Data Source
Figure 1~4
Figure 5~8
Figure 9~12
AI summary
The invention relates to a core layer, which is suitable for a multi-layer composite, which has at least a cover layer and a core layer, wherein the cover layer is arranged in such a way that the cover layer at least partially covers the core layer and is rigidly connected to the core layer, wherein the core-layer has elements made of wood, which have plate-shaped regions, which are arranged in a zig-zag shape, wherein a plate-shaped zig region of an element and an adjacent plate-shaped zag region of the element form a common edge between themselves in such a way that the zig-zag-shaped wood element is formed, wherein zig-zag shaped elements are arranged in the core layer in such a way that two such edges of two different elements cross each other at an angle that is not equal to zero and wherein the two elements are rigidly connected to each other at the crossing point. In one embodiment, a zig-zag shaped wood element can be adhesively bonded to a planar wood element in such a way that a zig-zag-shaped wood element is surrounded by two planar wood elements in the manner of a sandwich or in such a way that two zig-zag-shaped wood elements surround a planar wood element in the manner of a sandwich.