Patent Grant
8268431
The present application is a national stage application of International Application No. PCT/CN2008/071487, filed on Aug. 1, 2008. The PCT application claims priority to Chinese patent application No. 200710045737.5, filed on Sep. 7, 2007 and Chinese patent application No. 200810038705.7, filed on Jun. 6, 2008. The aforementioned PCT and Chinese patent applications are hereby incorporated by reference in their entirety.
The present invention relates to outdoor or indoor construction sheets and section materials, particularly relates to an apparently seamless lengthened sheet or section material made of bamboo, and a manufacturing method thereof.
The superiority of bamboo-like texture and flavor has made bamboo a leading choice in the field of indoor and outdoor decoration where styles are simple, unsophisticated and elegant. Commonly, bamboo sheets used in building constructions such as floors or wall panels are made by gluing and then pressing bamboo strips or blanks together. In a common pressing process of bamboo strips or blanks after they have been glued, there are three main factors which should be adjusted according to different thickness or properties of the bamboo strips or blanks: temperature, pressure and pressing time.
Bamboo strip here means a raw bamboo slat cut by woodworking machinery at any length or width according to its utilizability; and bamboo blank here means a bamboo plate formed by gluing and pressing several bamboo strips together in direction of width or length. As the same as wood, the process of lengthening the bamboo strips or blanks is necessary for forming bamboo sheets of a large area. One traditional process of the lengthening is to make a groove at one end of a bamboo strip or blank and a corresponding tenon at one end of another bamboo strip or blank, then engage the groove and the tenon with each other. There are two primary shortcomings of this kind of connection. First, because the tenon is simply embedded into the groove, or at most, an adhesive is used in addition to the connecting, the transverse connecting strength is weak. Second, this kind of connection results in an unattractive seam between the two pieces where dust or dirt can easily be trapped inside and is difficult to remove.
Bamboo is one of the most abundant natural resources in China. Although the sheet or section materials made of bamboo or wood seem very similar, there are a lot of differences between them actually. Bamboo is unique for its hollow interior and its stem is the only thing that can be used to make the sheets. Furthermore, bamboo canes normally have a big bottom and a small top, and that makes the bottom part of the stem much thicker than the top part. Also, with its tubular structure and curved surface, bamboo is limited in the applications as sheets or section materials. Generally, after peeling off the outer surface layer and inner surface layer, a rectangular bamboo strip unit is only about 0.3-1.0 cm thick, 0.5-2.5 cm wide, and is almost unable to be used as a long length section material.
A traditional process for making the bamboo sheets is to agglutinate and then press the bamboo strips or blanks together. According to the different specifications of bamboo strips or blanks, as wells as the nature of the adhesive, different temperature, pressure and pressing time should be chosen carefully.
Moreover, the existing technology is limited to the manufacturing of bamboo sheets, and the process of making bamboo section materials has not been established. For its extraordinary characteristics such as high stability, non-deformation, high hardness and strength, short production circle, etc., bamboo can be made into a section material of any thickness, width or length, so as to achieve the purpose of replacing lumber or even steel.
One object of the present application is to provide an apparently seamless lengthened bamboo sheet made of lengthened bamboo strips or blanks, which is strong and stable after the bamboo strips or blanks are connected transversely.
Another object of the present application is to provide a manufacturing method for the apparently seamless lengthened bamboo sheet.
The solutions of the present application are:
An apparently seamless lengthened bamboo sheet is formed by lengthening a plurality of bamboo strips or blanks to form a lengthened bamboo strips or blanks, and then assembling a plurality of lengthened bamboo strips or blanks together. Each bamboo strip or blank is characterized in that a slot is formed on at least one end of each bamboo strip or blank in the direction of its length, and a tenon corresponding to the slot is formed on the seam end.
The tenon on one bamboo strip or blank is embedded into the slot on another bamboo strip or blank. The tenon and slot are mutually matched so that the two bamboo strips or blanks are engaged to each other. The cross-sectional shape of the slot and the tenon can be of any kind, such as S shape, Z shape, zigzag shape, tooth shape, and is not restricted to the above. However, the shape is preferably not too complicated, as a complicated shape may lead to difficulties in manufacturing.
The engagement of the slot and the tenon is that the shapes of the slot and the correspondingly formed tenon are suited to each other. In this way, the tenon can be perfectly embedded into the slot and completely fill in it, so that a flat bamboo sheet of a consistent thickness is naturally formed. Furthermore, as a plurality of bamboo strips or blanks, which are formed by the same slotting process, can be connected to each other directly, the manufacturing process is dramatically simplified.
An acute-angle inward incline is formed on an outer edge of the tenon, and a corresponding obtuse-angle outward incline is formed on an inner edge of the slot to match the incline of the tenon. This design has two remarkable effects: first, the inward incline makes it easier for any two bamboo strips or blanks being connected to each other. In other words, the tenon can be embedded into the slot more easily; second, the inward incline can perfectly cover a seam formed between the two bamboo strips or blanks. Thus the apparently seamless lengthened bamboo product can be achieved after gluing and pressing.
Two slots, one on each end of a bamboo strip or blank, may open to the same direction or opposite directions, and two tenons corresponding to the two slots are formed on the same end, respectively. The two slots can be formed from the upper or lower surface of a bamboo strip or blank, or even from a lateral surface.
Slots on a bamboo strip or blank being formed toward the same or opposite directions merely cause different ways of connecting two pieces. If to the same direction, the adjacent bamboo strips or blanks are engaged to each other in a “face up-face down” way. Or if to the opposite direction, the adjacent bamboo strips or blanks are engaged in a consistent way.
In order to guarantee the apparently seamless lengthened bamboo sheet from breaking caused by stress concentration, at least a part of the joints should be staggered when a plurality of lengthened bamboo strips or blanks are assembled to form a sheet.
To further ensure the strength of the bamboo sheet, any two adjacent joints should be staggered when a plurality of lengthened bamboo strips or blanks are assembled. For a bamboo sheet of a relatively small area, any two joints should not be on the same beeline.
The bamboo blank is formed by gluing and pressing bamboo strips in direction of width or thickness.
A method for manufacturing the apparently seamless lengthened bamboo sheet includes the following steps:
In the second step, an adhesive is spread on the interface of the two connecting tenons, in order to enhance the strength of the engagement.
Alternative to the above-mentioned acute-angle inward incline, an obtuse-angle outward incline may be formed on the outer edge of the tenon, and a corresponding acute-angle incline may be formed on the inner edge of the slot to match the outward incline of the tenon. The outward incline is an alternative form of the inward incline. From the perspective of process, there is no difference between the inward incline and the outward incline, although the assembly of the bamboo strips or blanks might be easier with the inward incline.
The cross-sectional shape of the slot and the tenon can be a S shape, a Z shape, a zigzag shape, a tooth shape, a paw shape or an irregular shape. The shape can be any kind and is not restricted to the above. Any bamboo strip or blank which has a pair of corresponding slot and tenon formed on one end should be considered within the scope of this application. The cross-sectional shape is preferably not to be too complicated; otherwise it may lead to difficulties in the process.
For a surface (normally the upper surface that is exposed to viewers) of the bamboo sheet to look like seamless, it is enough that the tenon formed from the upper surface has an inclined end. Correspondingly, the inner side of the slot also has an incline. It is not necessary for any tenon or slot formed from the lower surface (unexposed) to be inclined. However, at the connecting joint, it would be better to form inclines on the end sides of both tenons formed from upper and lower surfaces, and that will make the bamboo strip or blank longitudinally symmetrical and easier to manufacture.
Yet another object of the present application is to provide an apparently seamless lengthened bamboo section material. The bamboo section material is formed by lengthening, gluing and pressing a plurality of bamboo strips or blanks together in direction of length, width or thickness. The resulting bamboo section material can be in pillar shape, board shape, or any other shapes.
The apparently seamless lengthened bamboo section material is formed by lengthening a plurality of bamboo strips or blanks and assembling a plurality of lengthened bamboo strips or blanks together. The bamboo strips or blanks are closely engaged to each other in direction of their length by a pair of corresponding slot and tenon, and lengthened bamboo strips or blanks are orderly assembled to each other in directions of width and thickness, so as to form a bamboo section material of a certain size.
Under the premise of maximizing the usage of bamboo, the apparently seamless lengthened section material of this application has little requirement on the selection of bamboo material. It is recommended to use the bamboo strip units of highest exploiting rate, which are 10 to 200 cm long, 0.5 to 2.5 cm wide and 0.3 to 1.2 cm thick.
The phrase “closely engaged” means that a slot or a tenon is formed on at least one end of bamboo strips or blanks in direction of length, and the tenon of one bamboo strip or blank is embedded into the slot of another bamboo strip or blank in order to connect with each other. The interfaces of the tenon and slot are a pair of corresponding inward and outward inclines.
In an embodiment, at the same end of a bamboo strip or blank where a slot is formed, a tenon is formed corresponding to the slot, and the slot and tenon are mutually matched. Therefore, the tenon of a bamboo strip or blank can be embedded perfectly into the slot of another bamboo strip or blank. By connecting one bamboo strip or blank to another, a bamboo section of infinite length can be naturally formed.
Additionally, an acute-angle inward incline or an obtuse-angle outward incline is formed on the end edge of the tenon, and a corresponding incline is formed on the inner edge of the slot to match the incline of the tenon. This has two remarkable effects: first, the incline makes it easier for any two bamboo strips or blanks being connected to each other. In other words, the tenon can be embedded into the slot more easily; second, the incline can cover the seam formed between two bamboo strips or blanks very well. Thus the apparently seamless lengthened bamboo section material can be achieved after gluing and pressing.
To ensure a smooth and apparently seamless appearance, the inclines should be adopted at least on an exposed surface of the bamboo section material.
Slots being formed toward the same direction or opposite directions merely cause the different ways of connecting. If to the same direction, the adjacent bamboo strips or blanks are engaged to each other in a “face up-face down” way. Or if to the opposite direction, the adjacent bamboo strips or blanks are engaged in a consistent way.
The apparently seamless lengthened bamboo section material is made by assembling the bamboo strips or blanks in direction of length, width and thickness. A method for manufacturing the bamboo section material comprises the following steps:
In the third step, the stacking single layered sheet A and/or single layered sheet B to a designated size include: stacking two or more single layered sheets A together, or stacking two or more single layered sheets B together, or inserting a single layered sheet A between two single layered sheets B, or inserting a single layered sheet B between two single layered sheets A.
The means of pressing are as follows:
Furthermore, one-time pressing is to stack three or more single layered sheets A and/or single layered sheets B together, and then pressing the stacked sheets by the press machine to form a bamboo section material of within 150 mm thick.
Hot-pressing is a technique in which a heated press plate is used to transfer heat to the internal of the material and adhesive under pressing, so that the adhesive will be cured and the materials will be glued together. Also, hot-pressing can be used for two-time pressing or multiple-time pressing to form multi-layered section material of a certain thickness. The process is to level and polish the surface of a single layered sheet at first, then to spread adhesive on the polished surface, and after stacking a plurality of the single layered sheets together, hot-pressing is carried out. This kind of hot-pressing process has the advantages of faster heat propagation, shorter glue curing time, no negative influence on both internal bonding strength of the adhesive, etc. so that the resulting products have a high quality and good performance.
In comparison, glue curing by traditional hot-pressing method cannot be used for products above a certain thickness, because the bonding strength is weak and the products are of low quality.
Under the method of this application, one-time pressing is enough for bamboo section materials within 150 mm thick; and two-time or multiple-time pressing is required for bamboo section materials more than 150 mm thick. Thus, this method can be applied in producing apparently seamless lengthened bamboo section material of 10 to 1000 mm thick, 10 to 1300 mm wide, and any length.
The “pressing” refers to hot-pressing, in which the temperature is 85 to 165 Celsius, and the pressure is 5 to 35 kg/cm2.
The “stacking” refers to two or more single layered sheets being stacked one on top of another concurrently or crisscross.
As bamboo may get moldy faster than wood, an anti-mildew treatment needs to be done to raw bamboo before producing the bamboo section material. The anti-mildew treatment is preferably a carbonization process, including water carbonization, wet carbonization or dry carbonization of the bamboo strips or blanks before lengthening.
The adjacent joints should be staggered when lengthened bamboo strips or blanks are assembled in direction of thickness and/or width.
The bamboo section material manufactured by the above method can be used as outdoor pillar, girder, railing, platform deck, platform flooring, outdoor or indoor flooring, truck sheet, ship floor, container panel, building board, etc. They can be used to replace any wood-based products or lumber products in building constructions.
The above-described bamboo blanks also include similarly pressed materials made of bamboo treads or sawalis.
The beneficial effects of the present invention are:
1. The apparently seamless lengthened bamboo sheet has a novel slot-tenon connecting structure which makes a seam between two adjacent bamboo strips or blanks appear unobvious on the surface of the sheet;
2. The connecting structure enhances the strength of the transverse connection;
3. The manufacturing method improves the utilization ratio of the bamboo material, adds values to the product, while protects bamboo natural resources;
4. The static bending strength, hardness and other mechanical properties of the apparently seamless lengthened bamboo section material are the same as the regular bamboo sheet, but the deformation degree drops down remarkably;
5. This application solves the long-time length limitation problem for bamboo products such as flooring, furniture panel, outdoor deck, garden planks, building material, etc. realizing the potential of replacing wood or even steel with the bamboo;
6. In the novel slot-tenon connecting structure, an acute-angle or obtuse-angle incline is formed on the end edge of the tenon. The incline not only provides the product with an apparently seamless surface after gluing and pressing together, but also enhances the transverse strength. The product's stability is enhanced dramatically;
7. The structure improves the utilization ratio of bamboo material, adds values to the bamboo product, while protecting natural bamboo resources; and
8. The bamboo section material, including pillar, girder, railing, platform deck and flooring, can be of any length, width and thickness as required. The bamboo section material is of high intensity, hardness and low deformation degree, and the products can replace wood or even steel.
The invention is further explained through the following examples in conjunction with the figures.
Referring to
Two slots 11, 11′, which face the same direction are formed on both ends of the bamboo strip or blank 10, and two tenons 12, 12′, corresponding to the slots 11, 11′, are formed on the same end, respectively.
On the same end of bamboo strip or blank 10, the slots 11, 11′ and the correspondingly formed tenons 12, 12′ are mutually matched to each other.
Acute-angle inclines 121, 121′ are formed on both end edges of the tenons 12, 12′, and corresponding obtuse-angle inclines 111, 111′ are formed on the inner edges of the slots 11, 11′.
Referring to
Referring to
A method to manufacture the apparently seamless lengthened bamboo sheet includes the following steps:
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An apparently seamless lengthened bamboo section material is formed by assembling and lengthening a plurality of bamboo strips or blanks together. The bamboo strips or blanks are closely engaged to each other in direction of length by a pair of corresponding slot and tenon, and assembled to each other in direction of width and thickness, so as to form a bamboo section material of a certain size.
The phrase “closely engaged” means that a slot and/or a tenon is formed on at least one end of bamboo strips or blanks in direction of length, and the tenon of one bamboo strip or blank is embedded into the slot of another bamboo strip or blank in order to connect with each other. The interfaces of the tenon and slot are a pair of corresponding inward (acute-angle) and outward (obtuse-angle) inclines.
Prior to manufacturing the apparently seamless lengthened bamboo section material, a carbonization process, which including one of water carbonization, wet carbonization and dry carbonization, is performed to raw bamboo strips or blanks. After that, the bamboo strips or blanks are assembled in direction of length, width and thickness. The manufacturing method includes the following steps:
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Spreading adhesive on both upper and lower surfaces of the one-time pressed bamboo section material 100/101, and then stacking two single layered sheets A 102, 103 to both surfaces respectively. The single layered sheets A 102, 103 and the one-time pressed bamboo section material 100/101 are concurrent to each other. A bamboo section material is formed by a two-time hot-pressing from the lateral side, in which the temperature is 85 to 165 Celsius, and the pressure is 5 to 35 kg/cm2.
Referring to
Spreading adhesive on both upper and lower surfaces of the one-time pressed bamboo section material 102/100/101, and then stacking two single layered sheets A 103, 104 to both surfaces respectfully. The single layered sheets A 103, 104 and the one-time pressed bamboo section material 102/100/101 are crisscross to each other. A bamboo section material is formed by a two-time hot-pressing, in which the temperature is 85 to 165 Celsius, and the pressure is 5 to 35 kg/cm2.
Referring to
Referring to
Spreading adhesive on both upper and lower surfaces of the one-time pressed bamboo section material 101/90/100, and then stacking two single layered sheets B 91, 92 to both surfaces respectively. The single layers and the one-time pressed bamboo section material are crisscross to each other. Forming a two-time pressed bamboo section material by a hot-pressing from the upper side, in which the temperature is 85 to 165 Celsius, and the pressure is 5 to 35 kg/cm2.
Referring to
Forming a bamboo section material 90/100/91 by hot-pressing from the upper side, in which the temperature is 85 to 165 Celsius, and the pressure is 5 to 35 kg/cm2.
Spreading adhesive on both upper and lower surfaces of the one-time pressed bamboo section material, and then stacking two single layered sheets A 101, 102 to both surface respectively. The single layers and the one-time pressed bamboo section material are concurrent to each other. Forming a two-time pressed bamboo section material by a hot-pressing from the lateral side, in which the temperature is 85 to 165 Celsius, and the pressure is 5 to 35 kg/cm2.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2007 1 0045737 | Sep 2007 | CN | national |
| 2008 1 0038705 | Jun 2008 | CN | national |
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/CN2008/071847 | 8/1/2008 | WO | 00 | 8/24/2009 |
| Publishing Document | Publishing Date | Country | Kind |
|---|---|---|---|
| WO2009/030132 | 3/12/2009 | WO | A |
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| 2417008 | Jan 2001 | CN |
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| Number | Date | Country | |
|---|---|---|---|
| 20100151175 A1 | Jun 2010 | US |
