LV14519B - Layered composite plate based on wood materials and provided with cell type hollow ribs - Google Patents

Abstract

There is proposed manufacturing technology of cell plastic type ribbed structure based on wood materials and manufacturing technology of layered composite plate(Fig.6) where in the middle layer is used proposed cell plastic type ribbed structure.

Description

Description of the Invention

BACKGROUND OF THE INVENTION The present invention relates to multilayer construction materials based on wood with specifically oriented fibers and mainly consists of sheet-like material with cellular ribs of a plurality of wood fiber finishing layers which are composite formed with a particular structure and glued together as multilayer structural material. wood elements and, as an interlayer, also fibrous composite materials made, for example, by impregnating fibers of plant origin with synthetic resin. The proposed layered composite slabs with a specific configuration of cellular hollow ribs could be used in the construction of industrial and communal buildings, mechanical engineering and transport, eg as load-bearing structural and containment elements in construction, as well as in wagon, ship, trailer and in the construction of motor vehicles, the manufacture of furniture, etc. spheres. The structure of the proposed laminated composite slab with cellular plastic hollow ribs increases the specific load-bearing capacity of the material under compression, bending, torsion, as well as combinations thereof, and significantly reduces the thickness of the slab from moisture.

Prior Art Analysis US 5,738,924 "Sandwitch construction building material" (SKI ¹ ' ⁷ B32B3 / 12) describes a three-layer structure building material comprising:

- at least one outer layer constituting the outer covering layer of the material selected from the group: plywood, fibreboard (which may in turn have cover layers), mineral slab, laminated wood sawn timber, synthetic resin layer, plasticised cement layer, cementitious layer mesh, laminate (laminate) or any combination of the above;

- an inner core layer extending between said outer cover layers and oriented perpendicularly thereto without movement, said inner core layer comprising at least one layer of natural wood with a fibrous cover layer consisting of axially disposed and resin-coated wood fibers, wherein: said core members are disposed such that the wood fibers are disposed substantially perpendicular to the finishing layer; said core elements being formed in such a geometric manner that the inner core layer is formed as a perforated openwork structure; said geometric shape being selected from the group consisting of: longitudinal plywood / veneer strips of corrugated configuration; longitudinal veneer / veneer strips with rectangular wave configuration;

longitudinal chip / veneer strips with rectangular wave configuration; veneer / veneer strips formed in a tubular configuration, wherein: opposite edges of said geometric shaped veneer / veneer core elements are in contact with said protective elements on each inner surface of the three-layer construction material.

Construction material as defined in patent LV133477, "Multilayer Construction Materials with Oriented Fibers", which is based on and described in U.S. Patent No. 5,738,924,

- that there is a panel structure (Fig. 1) made of different layers of anisotropic materials, preferably layers such as wood veneer, herbaceous and / or other vegetal fiber fibers with a directional orientation of certain lengths impregnated with synthetic resin;

- that all layers are integrated in a single multilayer structure such that a significant amount of fibers and the outer layers are oriented parallel to the panel surface in the required direction determined by the direction of load application, resulting in the peripheral layers working well in compression or tension;

- that in the layers forming the outer finishing layers on either side of the panel, a small amount of fibers is also perpendicular to the core amount of the panel-forming fibers in both the top / bottom layer and the inner layer, with the perpendicularly oriented fibers absorbing the stresses , also serves to stabilize the size, shape and strength properties of the material;

- that the inner material layer 4 has a honeycomb structure in which the walls / framework of the honeycomb elements are formed by fibers disposed at an angle of approximately 45 and 135 degrees to the outer layers and receive shear stresses.

A series of US patents (US 6511567, US6773791, US7255765, under the same title "Composite Building Components and Methods of Making the Same") define a method of fabricating ribbed building panels 2.1 through 2.7 and components 2.8 through 2.16 in successive post-operative operation, Fig. 2, which is characterized by the presence of corrugated ribs of various shapes in the middle panel layer, the orientation of which corresponds to the longitudinal and / or transverse orientation of the panel The three-dimensional configuration of the ribs 2.8-2.16 is formed by extruding composite decking / carpet Undoubtedly, the presence of such ribs in the middle of the panel or its member increases its rigidity, load-bearing capacity and specific strength under various loads - compression, tensile, bending, shear, both in the longitudinal and transverse directions of the panel; what m Whereas the corrugated rib forming technology essentially does not use the unique property of wood to have maximum load carrying capacity directly in the direction of the wood fibers, and it is therefore appropriate to modify the rib forming technology so that the orientation of the strength ribs and the wood fibers forming it are essentially perpendicular to the panel plane; of course, allowing the orientation of a certain portion of the wood fibers within certain angular limits, depending on the need to ensure the strength of this or that composite material.

It is well known that wood macrostructure is a cellular structure shown in Fig.3 and therefore various forms of prism or cylindrical structural elements are successfully used to improve the deformation behavior of wood materials, including the structure of so-called cellular plastics. (see Fig. 4) are disclosed in US6673415, "Honeycomb core material for sandwich structure and method for manufacturing the same" (SKI '- B32B3 / 12), the latter also known as European Patent EP1149691 (Fig.4 is taken directly from from this patent), patent JP 3753313 and others

EP 1149691 defines a sandwich core core structure comprising a cellular plastic backbone with a cell size of 3 to 100mm and a porosity of 92 to 99.5% and a filler for filling at least some of the cellular plastic material, including the filler, which is filled in its cavities, then whipped and hardened, containing: a material containing phosphoric acid; a hardener; a urethane prepolymer containing NCO groups; water and, if necessary, a blowing agent.

The general principles of mucous membrane formation have already been described in the Latvian Soviet Encyclopedia (LPE; Riga, Main Encyclopedia Edition, 1984, Vol. 9, p. 449). It emphasizes that cellular plastics are materials that consist of regularly spaced cells, usually of one or another polyhedron shape, the walls of which are made of a polymeric material (eg, fiberglass or other laminated plastic, polymeric film). Often cellular plastics are made by bonding hard, corrugated blanks and used in multilayer panels (more often triple panels, also known as sandwich panels). Such panels are lightweight, rigid, with good mechanical strength and are used in the manufacture of load-bearing structures, trim and soundproofing in aerospace, shipbuilding.

Developments in wood processing technologies in recent decades have led to the widespread use of layered wood materials (SKM) glued from many layers of veneer. SKM-based products are of great interest because this technology can create efficient materials for both the cellular peripheral surfaces and the central layer, because SKM is a pronounced anisotropic material and its layered composite panel structure can be oriented according to load direction. during operation.

K.Rocene's monograph (K.A.PoueHc "TexHOJiornuecKoe peryjiupoBaHHe cbohctb jtpeBecHH & i.", Pura, 3nHaTHe, 1979, 223 digits) describes the deformation behavior of laminated wood-based composites using a "layer-by-layer" approach.

- A) Feed matrices of multicomponent orthotropic and monoclinic composites are provided for all component composites with arbitrary orientation of the layers in the packing plane;

- B) the deformation model of flexible multilayer composites is generalized to be applied to unbalanced composites and to determine the components of their elastic yield and rigidity matrix, based on the deformation characteristics of the layers, their relative volumetric capacities and the order of the layers;

- C) compares experimentally obtained and theoretical results, for example, seven-layer balanced orthotropic boards based on wood, subjected to one-sided moisture effect, which results in asymmetric properties of the board relative to its median plane (i.e., composite becomes unbalanced), By comparing experimentally and theoretically obtained swelling and hazing results, the mean experimental results are in agreement with the theoretical values within the 98% confidence interval, and it has been shown that the layered composite exhibits both initial structural imbalance and eg due to exposure to ambient humidity and temperature during operation, leads to significant blistering, warping and, in a special case, corrugation of the slabs, which is not always negative. ultat, because the like. '' Defect '' can be transformed into an effect when used purposefully.

In addition to the aforementioned SKM fabrication technologies, the following techniques for making building panels using polymer and / or plastic and organic fiber compositions are also well known:

- D) by extrusion, the surface layers of the panel are made separately and the inner layers are separately made and then bonded together, eg glued to each other;

- (E) thermoforming, in the form of sheets or plates;

- F) using organic fibers as straw, wood fibers or other natural materials, mixing them with a thermosetting binder, filling the mass into a heated multiparticulate mold and then compressing the mold parts together until the end of the thermoforming reaction, to form sheet or plate products with: complex spatial structure, e.g. articles 2.1-2.7 shown in Fig.2.

Purpose and substance of the invention

The object of the invention is to increase the useful outcome of the laminated composite board with laminated wood-type ribs in the manufacturing process and to reduce the weight of these boards, while providing high physical mechanical properties and reducing the thickness change of the board from the action of moisture.

The proposed method of manufacturing ribbed laminated wood materials (SKMs) is defined in claims 1 to 5, and the associated method of making structurally balanced plywood as defined in claims 6 and 7 and its use is defined in claims 8. Some possible variants of the topological structure of the obtained layered composite with SKM ribs are shown schematically in Figures 5.1 - 5.6 from above, but Fig.6 shows schematically one variant of the layered composite plate using SKM rib structure 5.4 and made from of layers 1, 2 and 3 of three different materials, of which layers 1 and 2 are external and are not essential structural features of the invention. An important structural feature of the invention is the inner layer 3 of the laminated wood material with ribs of any configuration or with cavities filled with insulation and / or sound insulation, which can be of both regular and irregular shapes, such as natural wood, but it is important that said SKM ribs being formed as a lattice structure by interconnecting, at selected nodal points, SKM elements of this or other shape which are oriented perpendicularly or at a defined angle to the surface of said outer layers 1 and 2 and are based on laminated wood materials; (Fig. 7) made by any of the known techniques previously highlighted in italic font as signs C) and F): either directly by pressing a structurally balanced veneer package between the hot molded shelves of the required configuration or obtained by pressing a structurally unbalanced veneer The shear pack between the flat press shelves and the slanting of the SKM blanks is obtained by conditioning using the structural imbalance of the SKM plywood blade, moisture-temperature changes and shrinkage, swelling properties. Consequently, SKM rib walls form wood fibers which, depending on the rib size, curvature radius and the type of reinforcement chosen, are positioned at varying angles to the outer plywood layers and, depending on their location and orientation, receive compression, shear, tensile, torsion and bending effort.

All three layers of laminated composite board are glued together and form an integral structure in which the distribution of the amount of wood fibers in its individual layers and layers provides the load-bearing capacity of the board, while the rib structure provides effective control of material strength under various pressures, bending, shear , torsion, humidity and temperature, and a combination of these. Depending on the type of action, the proposed configuration of the SKM ribs will play a decisive role in the operation and therefore the shape and construction of the middle plywood ribs, determined by the bundle structure and the fiber orientation of the wood fibers in the individual SKM layers.

In order to make the large plywood panels according to the invention (Fig.6), two preformed and uniformly structured large flat panels are taken and used as the outer plywood plywood as well as the prior art corrugated plywood sheets. made either as curved sheets or as large flat sheets made in a flat press, initially being structurally unbalanced with respect to the middle plane before extrusion. As described in more detail in steps 1-5, to form the SKM structure as a finished middle layer of the sandwich composite slab, the corrugated plywood elements (3.1) and (3.3) are glued to a flat plywood or other wood material (3.2), which serves only as an auxiliary sheet for forming the SKM structure on one or both sides (Fig.6), and the resulting SKM blank is then divided into elements for making ribbed SKMs (Fig.7), orienting the elements accordingly and placing one next to the other ( -o) in the direction (s) of the coordinate axis (s) and in separate areas by gluing continuously in a ribbed structure along the length and / or width (Fig. 5).

According to the invention, triple-layered, in some cases multiple-layered, composite slabs with SKM-type hollow or heat-insulated ribs are intended to be used not only in lightweight enclosures (self-supporting wall elements, office work area separation panels, etc.), but also of such type. in structures such as floor, wall, ceiling slab construction, ship, trailer and wagon construction including furniture industry etc.

SKM ribs can be filled with soundproofing and / or heat insulating materials, such as foam polystyrene (Fig.6, 3.4), as well as all or some of the wood material can be treated with antiseptics and / or flame retardants to prevent burns, rot and insects damage. As a result, the proposed layered composite slab with SKM ribs has increased strength per unit weight / weight and requires relatively small amounts of material to be manufactured.

It is desirable that all of the above SKM rib characteristics be selected based on the geometric and defonative properties (thickness, relative bulk density and layer / orientation) of all SKM layers used to build them, taking into account the normative characteristics of the building panels (mainly strength, shape stability). conditions, thermal and acoustic insulation) for this or another application. The laminated composite slab can then be safely used as building panels according to the invention, for example, but not exclusively in various indoor structures.

Examples of realization of the invention (see Figs. 5,6 and 7)

FIG. 5 shows some variants of the SKM rib configuration, with: 5.1 and 5.2 being an interconnected rib; 5.3 is an unrelated rib; 5.4, 5.5 and 5.6 are variants of a combination.

Figure 6 shows a sandwich composite slab with a SKM rib, with:

- 6a is a panel design where: 1 is the top panel, 2 is the bottom panel, 3 is the SKM rib;

- 6b is the rib of SKM, where: 3.1 is a corrugated plywood element; 3.2 is an element of flat plywood; 3.3 is an element of corrugated plywood;

6c is a rib of SKM with a cavity filling 3.4, wherein 3.1, 3.2, 3.3 are the same elements as Figs. 6.b.

Fig.7 shows the variants of SKM rib cutting: 7.1 - perpendicular to the rib cavity axis, 7.2 - below the angle to the rib cavity axis; 3 is the same as FIG. 6.a.

Example 1: The layer (1) and layer (2) of the sandwich composite slab with the SKM rib shown in Fig.6 are each formed according to a prior art, while the layer (3) is formed as the SKM rib according to the invention, wherein the ribs (Fig. .6, 3.1, 3.2, 3.3) arranged in a layer (3) of laminated composite slabs are formed by sawing the SKM rib (Fig.7) consisting of layers (3.1 3.3) in and between 20..500 mm high ribs. The layer (3) is arranged in the pattern 5.1 shown in Fig. 5 and glued to the outer layers (1) and (2) to form an integral sandwich composite panel structure. If necessary, after gluing the layer (2) to the layer (3), fill the cavities of the layer (3) with heat insulating and / or soundproofing material (Fig. 6.c, 3.4) and then glue the layer (1).

Example 2: According to the invention, the middle layer (3) of the laminate composite panel is formed as a SKM rib from 20..500 mm thick elements obtained by sawing a 50..400 mm thick SKM rib (Fig. 7.1, 7.2) in which the corrugated sheets (3.1) ) and (3.3) were formed by pressing a package of structurally unbalanced feedstock between flat press racks and then conditioning the resulting workpiece under conditions similar to those of the operation, but after a certain period of heat treatment and at a given mode providing the necessary dampening wherein: the SKM-forming elements in a layer (3) are arranged in an article analogous to one of the articles 5.1, 5.2 shown in Fig. 5. 5.3, 5.4, 5.5 or 5.6; a portion of the SKM rib forming elements are sawn from the previously obtained SKM rib, e.g., below 45 ° to its longitudinal axis (Fig. 7.2), and the layer (3) is positioned below a defined angle from 0 to 180 degrees to the outer the sheets (1 and 2) of the sheet longitudinal axis (see Fig. 5), whereby the voids of the layer (3) can be filled with heat insulating material (Fig. 6.c, 3.4), if necessary. After the layer (3) is glued to the layer (2), it is glued to the layer (1).

Example 3: In the layered composite slab construction (Fig.6), according to the invention, the inner layer (3) is formed as a SKM rib analogue as defined in the previous examples, while the outer layers (1 and 2) are formed as materials selected from the group: layered composite slab, fiber panel with or without corrugated internal reinforcement based on SKM analogue as shown in Fig.6; a sheet of metal, a mineral plate incorporating directional wood fibers; wood-based sawn timber; cement layer in combination with reinforcing wire mesh; chaotic wood and glass or carbon fibers or textile fibers or canvas of synthetic materials or any combination of the above, incorporated in a synthetic resin; wood-based composite material obtained from organic fibers using straw or other natural material mixed with a thermosetting binder.

Example 4. According to the invention, the inner layer (3) is formed by cutting transversely (Fig.7.1) or below the angle (Fig.7.2) of the SKM rib and placing the obtained elements in a layer (3) in the pattern shown in Figs. 5. Thus, the SKM layer (3) is designed as a ribbed structure, the element walls / framework of which are made of wood fibers with a orientation in a wide range of 0 to 180 degrees with respect to the outer layers (1 and 2), which ensures absorbs shear, torsion and bending effort. All or individual elements of the board may be treated with antiseptics and / or flame retardants to prevent burns, rot and insect damage. Applying commonly known technologies for the production of wood-based plywood and board, sandwich composite panels with a predefined SKM ribbed layer (3), the voids of which can be filled with insulation and / or soundproofing material, can be used as building panels. There is no technological problem in making building panels with a thickness of 100 mm to 600 mm, the size of which is limited only by the size of the shelves of the press plates.

Claims (8)

Claims A method of making a cellular plastic type ribbed structure based on wood materials, characterized in that said cellular plastic ribbed elements are made as follows: a) making the required number of identical SKM corrugated blanks, which are glued in pairs to form a cellular internal structure on both sides of the auxiliary plate, aligning the waveguides of the opposite corrugated blanks and the locations of the slots on opposite surfaces of the auxiliary plate; a number of said corrugated SKM blanks are glued to the auxiliary plate on one side only to cover the cellular plastic around the perimeter by placing the smooth surface on the outside; b) The corrugated blanks produced in step a) are sawn in a plurality of bands by moving the cutting tool in the first direction, i.e. perpendicular to the corrugated wave backs, and the resulting bands are fabricated in the second direction perpendicular to said second direction, guiding the cutting tool through selectively selected corrugated grooves, whereby it is not mandatory to saw through all the grooves if the size and / or width of the resulting cellular plastic exceeds the size of the resulting cellular plastic in the first cutting direction; c) to form a cellular plastic structure in which the ribs from above form a lattice structure, such as shown in one of the drawings (see Fig. 5), having a constant height equal to the size of the elements made in step b) cellular elements made in the direction b) of step b) to form an integral length and width of the required cell structure and required cell size, coaxially arranged according to the pre-selected cellular plastic configuration, and where necessary secured along separate lengths with glue, e.g. ., analogous to forming bevel-glued butt joints or tangential overlaps, whereby the outer covering surface of the cellular plastic is preferably formed from the cellular plastic elements obtained in step b) by sawing the corrugated SKM blanks which were glued to the a) auxiliary plates only on one side, pointing flat mu to the outside. The method of claim 1, wherein the cellular plastic cavities between the ribs are filled with sound-proofing and / or heat-insulating materials, e.g., foam polystyrene. The method according to claim 1 or 2, wherein the characteristics of the plastic ribs of all said cells are selected based on the geometric and deformation properties (thickness, relative volume and layering / orientation order) of all SKM layers used to form them. taking into account the normative characteristics of laminated composite panels (mainly strength and shape under service conditions) for this or another application, the structural elements obtained in the cellular fiber manufacturing process are orientated accordingly and arranged side by side in the desired coordinate axis (s) (s) and in separate areas are glued together in a continuous ribbed structure along the length and / or width. The method according to any one of claims 1 to 3, wherein said SKM corrugated blanks are made of veneer layers having topological structure variants shown in FIGS. 5.1 to 5.6 depending on the angles of orientation of the wood fibers in the adjacent SKMs, the number and thickness of the layers and the method of reinforcement chosen. The method of claim 1 or 2, wherein said SKM corrugated blanks are made in one of the following embodiments: - a large flat plate is produced in a flat press, initially forming a structurally unbalanced structure with respect to the middle plane before pressing, but the resulting flat plate is itself transformed into said corrugated SKM during conditioning, e.g. used in steps a) to d) to produce a ribbed cellular plastic structure, - In a two-part mold with a selected surface relief, the largest possible size of the curved glued element is formed, before forming it as a structurally balanced structure with respect to the median plane, and the resulting corrugated SKM is used in steps a) to d) A method of manufacturing a laminated composite panel with cellular plastic hollow ribs based on wood materials, characterized in that the cellular plastic sheet as defined in claims 1 to 5 with an SKM rib is adhered to the prefabricated panel as an integral structure over the entire free surface area. top and bottom layers, each of which may be any composite material of desired structure, preferably structurally balanced, on wood, etc. bases of suitable materials, possibly all or part of the structure of the board being treated with antiseptics and / or flame retardants against burning, rotting and insect damage, and, if necessary, covered with metal, plastic, etc. suitable sheet material as additional overlay. The method of making a plate according to claim 6, wherein the structure of both said outer layers and the structure of the cellular plastic hollow ribs which are glued together and form an integral plate structure are chosen so as to provide maximum effective control of the specific strength of the material. loads - compression, bending, shear, torsion, as well as the combination of these loads. Use of a board made by a method as defined in claim 6 or 7, using a method of fabricating a cellular type ribbed cellular structure of the type defined in claims 1 to 5 in lightweight enclosures (self-supporting wall elements, office work area). partition panels, etc.) as well as load-bearing structures such as floor, wall, ceiling slab construction, ship, trailer and wagon construction including furniture industry etc.