Patent Application
20240416548
The invention relates to a method for producing cross-laminated timber panels with cutouts that are constructed, in particular are composed of, at least one longitudinal layer, in which the boards are arranged in rows parallel to each other in a longitudinal direction, and at least one transverse layer, in which the boards are arranged in rows parallel to each other in a transverse direction. According to a second aspect, the invention relates to a wooden panel production device.
EP 3 542 981 B1 discloses a press for pressing and glueing wooden boards to produce laminated panels. This press can be used to produce, among other things, wall elements composed of boards that have cutouts for windows or doors; to this end, planks of varying lengths can be introduced one after the other into the joining system where they are positioned and, once positioning is complete, pressed together. However, the individual boards only extend with their longitudinal axis in the longitudinal direction of the panel.
To obtain sufficient stability of a wall element, multiple wooden panels should be glued together to create a cross-laminated timber panel in such a way that the longitudinal axes of the boards intersect in overlapping wooden panels, i.e. these are arranged alternately parallel in a longitudinal direction and a transverse direction. For example, in the outer layers the longitudinal axes of the boards extend in the transverse direction to the wooden panel and, in the at least one inner layer, in the longitudinal direction to the wooden panel. Basically, the individual panels are always glued together to form a cross-laminated timber panel in such a way that the longitudinal axes of the boards of adjacent layers intersect.
EP 3 795 315 B1 discloses a press with which wooden boards of any desired width and length can be continually glued to create laminated wooden panels of any desired width and length without the surface of the laminated panels being subsequently processed. If the wooden boards are not to be glued together to form laminated panels, the joining system should be used as a cross conveyor.
It is advantageous to produce cross-laminated timber panels that are to be used as wall elements in house construction directly with window and door cutouts, as this saves material and avoids waste. The problem during production of such cross-laminated timber panels is that the boards for the wooden panels must be laid and glued once in their longitudinal direction transverse to the longitudinal direction of the desired wooden panel (transverse layer) and once in the longitudinal direction of the desired wooden panel (longitudinal layer). This requires two different joining systems.
DE 10 2010 026 578 B4 presents a method for producing a cross-laminated timber panel where a longitudinal layer of boards is first laid, said boards being aligned in the longitudinal direction of the cross-laminated wooden panel so that at least one of the boards protrudes beyond the other boards in the longitudinal direction. A first transverse layer of boards is then laid on the first longitudinal layer, said boards being aligned in the transverse direction of the cross-laminated timber panel. The layers are subsequently pressed in the longitudinal direction, the transverse direction and in the direction perpendicular to both directions.
EP 2 618 972 B1 discloses a method for producing multi-layer panel elements in which the boards are of different lengths to form a cutout and are positioned according to the position of the cutout.
EP 1 369 214 B1 presents a method for joining multi-layered panels in which the positions for nailing the boards are calculated using the board widths of the previous layer and the nailing positions of the subsequent row are matched to the underlying boards.
WO 2012/104100 A1 discloses a method for fitting a multi-layer solid wood composite component with at least one layer of boards orientated parallel to one another and pivoted relative to the boards of the preceding layer. The boards are placed one after the other on the top layer and nailed to this layer or the layer below it on a stationary portal until a layer is reached on which the next layer is placed.
The invention aims to produce both the longitudinal layer and the transverse layer of a cross-laminated timber panel in the same or an identical jointing system.
According to a first aspect of the invention, the problem is solved in a method comprising the following steps:
These steps render it possible to produce the longitudinal layer and the transverse layer in one and the same joining system or in two structurally identical joining systems because only longitudinal layers are laid and pressed and the transverse layers required are created by dividing a second longitudinal layer into multiple partial panels and rotating the divided parts by 90°. The longitudinal direction of the boards in the individual layers thus runs at right angles to each other. The size and number of partial panels required must of course be calculated in advance. It is also possible to re-divide partial panels.
The two outer layers of a cross-laminated timber panel are preferably composed solely of wooden panels that have been glued together. In the inner layers, an insulating panel can be arranged between two boards. The insulating panel can be wider than the boards. In the joining station, wooden boards and fiber panels, preferably wood fibre panels, are then glued together alternately at the sides.
Preferably, one row contains a maximum of five individual boards.
In one embodiment example, the boards are transported to the joining station in the longitudinal direction and positioned via adjustable end stops. After positioning, they are introduced into the joining station in the transverse direction, i.e. transversely to their longitudinal axis.
It is advantageous to trim the lateral edges of the glued cross-laminate timber panels before further processing so as to calibrate them and therefore achieve the desired final dimensions.
At two opposite lateral edges (right and left in the diagram, or at the beginning and end in the longitudinal direction), the longitudinal layers, which are later to be used as transverse layers, are preferably bordered by solid wood, i.e. boards, if fiberboards are placed between them.
According to a second aspect, the invention relates to a wooden panel production device for producing cross-laminated timber panels with cutouts that are constructed of at least one longitudinal layer, in which the boards are arranged in rows parallel to each other in a longitudinal direction, and at least one transverse layer, in which the boards are arranged in rows parallel to each other in a transverse direction, with
The cut-off device is, for example, a milling tool or a saw, in particular a chop saw or a circular saw.
The rotation device is, for example, a rotary tilting table, a rotary damper, a rotary flap, a rotary carousel, a gripper, a lifter, in particular a vacuum suction cup or a vacuum lifter, or a handling robot.
Preferably, the wooden panel production device has a joining device which is configured to place the transverse layer Q on the longitudinal layer L and to glue the overlapping layers together. The joining station preferably comprises the joining device; alternatively, it is designed as a separate device.
Preferably, the wooden panel production device has a longitudinal layer formation device, which is configured to form the second longitudinal layer from a plurality of individual boards in multiple rows to create the cutouts, wherein individual boards are laid in several rows and glued together on their longitudinal sides to allow for the cutouts, the second longitudinal layer being stepped in the transverse direction RQ, wherein the area of the second longitudinal layer corresponds to the area of the first longitudinal layer without the cutouts, The joining station preferably comprises the longitudinal layer formation device. In this case, the second longitudinal layer is produced in the same device in which it is later reassembled as a transverse layer. Alternatively, the longitudinal layer formation device is separate.
In a preferred embodiment, the wooden panel production device has a transport device, which is configured to transport the boards in the longitudinal direction to the joining station and has adjustable end stops for positioning the boards, and a pushing device, which is configured to introduce the boards into the joining station in the transverse direction after positioning. For example, the transport device is an electric pallet conveyor, a vehicle, in particular an autonomous vehicle, a lift, a shaft conveyor, an overhead conveyor, an aerial tramway, a trolley conveyor, a rail conveyor, a roller conveyor, a belt conveyor, a chain conveyor or an underfloor drag chain conveyor. The pushing device is, for example, a slide, in particular a mechanical, pneumatic or hydraulic slide.
The wooden panel production device preferably has a trimming device that is configured to trim the cross-laminated timber panels before they are processed further in order to calibrate them. The trimming device is, for example, a milling tool or a saw, in particular a circular saw.
Preferably, the joining station is configured to arrange an insulating panel between each of the boards for the transverse layer. The insulating panels are preferably wider than the boards.
The wooden panel production device preferably has a control device, which is configured to control the longitudinal layer formation device of the cut-off device, the transport device, the glueing device, the joining device, the rotation device, the pushing device, the trimming device, the rotation device and/or the joining device, so that the wooden panel production device automatically conducts the method according to the invention.
In the following, an embodiment example of the invention will be explained in more detail with the aid of accompanying figures. They show:
The second uncut board L2 is then coated with glue, especially a hot melt adhesive, on the longitudinal edge facing the first board L1, introduced into the joining system 1, transported up to the end stop 1, and then pushed in the transverse direction RQ against the first board L1 and pressed with it. The contact between the hot melt adhesive and the longitudinal edge of the first board L1 causes the former to cure quickly, fixing the two boards L1, L2 together.
To begin the window cutout A1, the next board L3 is designed to be shorter. It is glued on its lateral side facing the second board L2, transported into the joining system up to the end stop 1, then pushed in the transverse direction RQ against the second board L2 and joined to it using the hot melt adhesive.
The fourth board L4 is designed to be even shorter and, after first being glued on its lateral edge facing the third board L3, is transported into the joining system up to the end stop 3 and then pushed in the transverse direction RQ against the board L2 and joined to it. Accordingly, the next cut boards L5, L6, up to L21 and L22, are glued in order to form the first part of the door cutout A2, moved into the joining system against end stop 1, end stop 2 or end stop 3, and joined in the transverse direction so as to join them with one or the previously glued boards L1. This produces a longitudinal length L.
For practicality, the boards Li in a row I, II, . . . IX, X are first positioned and then moved together against the previously laid boards. This means that, in row IV for example, board L5 is initially transported against end stop 1, board L6 against end stop 2 and board L7 against end stop 3, then all three boards L5, L6, L7 are pushed together against the boards L3 and L4 previously joined in row III and pressed in order to fix them (see
To obtain a stable wall element, a cross-laminated timber panel must be produced and a transverse layer Q glued to the longitudinal layer L using wood glue and then pressed. In the process, the cutouts A1 and A2 must of course be in the same location.
The door cutout A2 may render the cross-laminated timber panel unstable during transport to the construction site. To avoid breaking or tearing, boards L21 and L22 could be made as a single long board the door cutout then completed by cutting this last board once at the construction site.
The transverse layer Q to be glued to the longitudinal layer L can be seen in
How the transverse layer Q is produced is shown in
First, a second longitudinal layer LZ is produced in a longitudinal layer formation device, not depicted, with boards Bi, which are aligned with their longitudinal axes in the longitudinal direction RL. Production is carried out as described above. For example, the joining station 200 can comprise the longitudinal layer formation device, so that the second longitudinal layer LZ is produced in the same device in which it is later reassembled as the transverse layer Q.
The three upper boards B1, B2, B3 in rows I, II, III extend across the entire length. Conversely, boards B4 to B11 in rows IV, V, VI are designed to be shorter, resulting in a stepped panel in the longitudinal direction RL.
The finished wooden panel (top right-hand illustration) demonstrates that different sized panels A, B, C, D, E, F can be positioned next to each other and glued together to form the cutouts A1, A2. The size of panels B and C and E can be calculated from the size of the cutouts A1, A2 to be produced. The size of panels A, D and F can also be calculated. Correspondingly, boards B1, B2, . . . B1, . . . B10, B11 are cut to size using a cut-off device 150, for example in the form of a chop saw, and laid such that smaller partial panels A, B, C, D, E and F can be cut from the laid wooden panel, which is visible in the bottom left-hand illustration.
In the transition from the lower to the upper illustrations, the divided panels are rotated by 90°. Here, panel F, which was cut off at the rear end of the laid wooden panel, is rotated first, transported in the transverse direction RQ and positioned by guiding it against an end stop that is not visible. The partial panel E is then rotated by 90°, glued with hot melt adhesive on its right-hand lateral edge as shown in the drawing, transported in the transverse direction RQ and pushed against the already positioned partial panel F and pressed together with it. In the same way, the partial panels D, C/B and A are each rotated by 90°, positioned in the transverse direction RQ if necessary and joined to the already positioned partial panel with the glued lateral edge.
As can be seen in the lower illustrations in
The cross-laminated timber panel can basically be constructed and/or consist of any number of wooden panels. Three-ply and five-ply cross-laminated timber panels are preferred, but seven-ply and nine-ply cross-laminated timber panels are also produced. It is important that the course of the longitudinal axis of the boards Li, Qi of the adjoining panels cross each other.
The functional sequence for joining the boards L1, L2, . . . Li . . . L22 is described below with reference to
A continuous roller bar with rollers, which can be adjusted to the board thickness, is arranged above the transport device 100. These non-driven rollers ensure the safe movement of short and light components.
The diagram in
All five end stops are positioned in the position of the front edge of the respective board above the transport device 100. The last end stop 1 is at the position of the longest board in the throughfeed direction R. Each end stop has a sensor before the stop position that recognizes the approaching board Li. The transport device 100 is divided into several short, individually driven sections. Depending on the length of this board, the relevant roller conveyor sections are lowered so that the front edge moves into the lowered end stop and is stopped exactly there. All end stops 2 to 5 positioned in front of this stop allow the first board to pass through. Their sensors count the passes. End stop 2 allows a board to pass through and stops the second board that follows. End stop 3 allows 2 boards to pass through and stops the third board etc.
As can be seen in the path-time diagram in
Once all the boards are in position, they are pushed to the side of the transport device 100 by a pushing device 103, for example in the form of a side pusher. This side pusher 103 is arranged like a comb between every second roller 101 (see
With the wide roller conveyor 100 and the large adjustment path of the side guide, the joining station 200 is also suitable for the lateral joining of wider wood fiber panels.
These panels enter the joining station from the opposite side and are positioned with an additional pusher (not shown). The side guide is also used to push off the fiberboard completely. They are equipped with powerful actuators n for this purpose. The side pushers 103 then remain in the lowered position. The side guide must be moved back into position until the next board can be fed in.
Swivelling hydraulic pushers with a narrow spacing of 250 mm take over the laterally pushed boards and press them sideways. All 66 pushers always work over the entire length of the joining station 200, regardless of whether there is a board or a gap. They all run up against a fixed end stop. This ensures that the rear edge of all pushed and glued boards is always in a straight line. In addition, a synchronised shaft over the entire length of the joining station 200 ensures that all sliders move forwards in parallel. Gear wheels and gear racks engage under the sliders. These sliders have a travel distance of 340 mm for maximum 280 mm wide boards. Optionally, travel limiters can be swivelled in to limit the travel for narrow boards to 80 to 140 mm. This allows the cycle time for compacting and returning to be reduced.
Only the immediately preceding board (Ai, Bi) is held in a stable clamping device from above, pressing onto the sliding base and aligned in height. The clamping pressure generates the counter-pressure for joining and levelling. The hydraulic sliders have so much force that they always move to their end position. The clamping devices are also arranged and controlled in a tighter grid of 250 mm. In a gap in the joining plane, which forms a cutout A1, A2, they must not exert any counter-pressure so that the section behind can continue to move freely (see
A wall element is composed of several longitudinal layers L and transverse layers Q glued together. The two outer panels are usually transverse layers. In order to achieve good insulating properties, insulating boards (e.g. made of wood fibers) can be inserted between the individual boards in the layers used as intermediate layers.
The insulating boards can be wider than the boards for the longitudinal layers Li or the transverse layers Q1. It is advantageous if the panels made with insulating boards are bordered by solid wood on their outer edges. The division when laying the longitudinal layers L or transverse layers Q must then be taken into account accordingly. In the joining station, wooden boards and fiberboards are then glued together alternately at the sides.
The transverse-layer board is first divided into various rectangles, A, B, C, . . . . The width of these rectangles (transverse to the running direction of the boards Bi) must not be greater than the maximum width of the side joining station. In this case, the rectangle A would be divided into several sections A1, A2, . . . An.
These rectangles are rotated by 90° and placed next to each other, resulting in the total length of the first board B1. The required lengths and positions of boards B2 to B11 are then calculated accordingly (
| Number | Date | Country | Kind |
|---|---|---|---|
| 10 2023 116 006.0 | Jun 2023 | DE | national |
