Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B21/00—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board
  • B32B21/13—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board all layers being exclusively wood
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
  • B27D—WORKING VENEER OR PLYWOOD
  • B27D1/00—Joining wood veneer with any material; Forming articles thereby; Preparatory processing of surfaces to be joined, e.g. scoring
  • B27D1/04—Joining wood veneer with any material; Forming articles thereby; Preparatory processing of surfaces to be joined, e.g. scoring to produce plywood or articles made therefrom; Plywood sheets
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B21/00—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board
  • B32B21/10—Next to a fibrous or filamentary layer
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B21/00—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board
  • B32B21/14—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood board or veneer
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
  • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
  • B32B5/022—Non-woven fabric
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
  • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
  • B32B5/024—Woven fabric
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
  • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
  • B32B5/06—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer characterised by a fibrous or filamentary layer mechanically connected, e.g. by needling to another layer, e.g. of fibres, of paper
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B9/00—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00
  • B32B9/02—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising animal or vegetable substances, e.g. cork, bamboo, starch
  • B32B9/025—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising animal or vegetable substances, e.g. cork, bamboo, starch comprising leather
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B9/00—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00
  • B32B9/04—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising such particular substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material
  • B32B9/047—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising such particular substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material made of fibres or filaments
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2317/00—Animal or vegetable based
  • B32B2317/16—Wood, e.g. woodboard, fibreboard, woodchips

Definitions

• Laminates having two or more blocks joined to each other have been used for a long time for manufacturing various articles.
• Examples of laminates made of wood blocks include plywood.
• wood laminates have been primarily made by using adhesives.
• An adhesive layer is most of the time weaker than wood material and, furthermore, it is also more sensitive to excess moisture, dryness and several chemicals.
• An adhesive may also cause discolorations. Due to the weakness of an adhesive layer, the glued laminates are susceptible to peeling when subjected to overstress or otherwise demanding conditions. Adhesives may also be toxic to the environment.
• An object of the invention is to provide a method for overcoming the above drawbacks and capable of producing an article which does not require an adhesive layer.
• This invention discloses a novel structure, wherein the layers of a laminate are joined primarily in a mechanical fashion by needle punching.
• one of the layers to be joined consists of original wood material and the other may consist of some fibrous material or also of original wood, in which case the question is about laminating wood sheets on top of each other.
• needle punching which is prior known from textile technology and used for joining textile materials, such technique being described e.g. in US Patent No. 3,483,601.
• needles are punched through superimposed layers with barbs or other such members included in the needle detaching fibers or wood grains from the upper layer an carrying them into a wood block set underneath to join th layers to each other mechanically through binding by th fibers or grains.
• needle punching can be effected mechanicall in a device, wherein needles are mounted side by side o an up and down movable needle bar, under which the layers to be joined for a wood laminate are brought in a manner that the needles are driven through an upper layer of wood or a fibrous textile material into a lower wood layer, followed by withdrawing the needles up and out of the wood material.
• the resulting mechanical bond is sufficiently strong and no adhesive is required in lamination.
• Fig. 1 shows an article of the invention consisting of wood blocks, which form superimposed layers,
• Fig. 2 shows a needle punching operation of the invention when manufacturing the article of fig. 1,
• Fig. 3 shows a second laminating method for wood blocks
• Fig. 4 shows a third laminating method for wood blocks
• Fig. 5 shows a method, wherein the wood blocks consist of separate elements
• Fig. 6 shows a method, wherein a fibrous textile material is laminated on top of a wood block
• Fig. 7 shows a method, wherein the article is given desired shape during the course of needl punching.
• FIG. 1 An example of a laminate 10 is shown in fig. 1.
• Super ⁇ imposed, flat wood blocks 1 of original wood material are secured to each other by means of wood grains 2.
• Fig. 2 illustrates needles 3 in the process of penetrating through wood blocks 1 with wood grains 2 carried along.
• the wood blocks can be either flat-shaped, e.g. in the shape of a board or a veneer as in figs. 1, 2, 3 and 4, but also chip-shaped as in fig. 5, whereby it is possible to use e.g. wood chips and to provide a chipboard-substituting structure.
• the wood blocks can have any other arbitrary shape for producing layers laminated mechanically on top of each other.
• FIG. 3 illustrates a laminate, wherein wood blocks 1 provide layers between which is laid a fibrous material 4 carried by means of needles 3 into the interior of wood blocks for an increased aggregation force therebetween. Another possibility is to lay between wood blocks 1 some material other than fibrous, such as a film, with portions thereof being drawn by needles 3 into the wood.
• Fig. 4 illustrates granular particles 5 of a material other than wood, laid between the layers produced by wood blocks 1.
• Various types of fibrous mate ⁇ rials, films or grains between wood layers can be combined in a single laminate, as desired.
• the directions of wood blocks in a laminate can be selected in an arbitrary fashion as the case may require, as shown in figs. 2, 3, 4 and 5.
• the same wood laminate can be run through a needle-punching process either once or several times.
• the needle punching can be effected either from one side of a laminate only or from both sides.
• said needle-punched wood laminate 10 can be compressed and/or heated. Heating can be effected by partially or completely melting fibers 4 or film portions or granular particles 5, if they are e.g. some thermoplasti material, for the firm adherence between the wood-blocks binding wood grains 2 and the actual wood blocks 1. Durin the course of heating, the laminate can also be moulde into any desired shape.
• the punching depth of needles 3 it is possibl to determine the appearance of laminate surfaces (figs. and 3) as well as the number of transferred wood grains or fibers 4, film sections or granular particles 5.
• B selecting the shape of the needles it is also possible t contribute to the outcome of needle punching, as shown i figs. 2 and 3.
• Figs. 2 and 3 illustrate also that a plura lity of wood blocks 1 can be joined by needle punching.
• the needle punching density refers t the number of needle stitches per unit area of a surfac to be needle punched, in this case, that of a wood laminate.
• Needle punching can also be used for providing the surface of wood or a wood laminate with other types of coating materials, e.g. a fabric, as shown in fig. 6, wherein a wood surface 6 is covered with a fabric 7, followed by selecting a suitable needle punching depth and performing the needle punching itself.
• the coating material e.g. fabric 7, laid upon a wood surface is secured to wood surface 6 by means of fibers 8 penetrating therefrom into the interior of wood as a result of needle punching.
• the same principle can also be applied for covering a wood surface with a non-woven fabric.
• the same technique can be applied for fixing all such layers which, upon needle punching, release components which mechanically secure the layer to a wooden surface.
• FIG. 7 illustrates how a composite element 10 manufactured by needle punching wood blocks 1 can be given a desired shape, such as a curved shape, during the course of needle punching provided that blocks 1 consist of sufficiently flexible layers. This can be achieved by using sufficiently flexible flat blocks 1 or arbitrarily shaped blocks 1, as those shown in fig. 5.
• the needle punching is performed by punching the blocks against a perforated support 9 of a certain shape.
• the original wood used in the invention may comprise a chipboard manufactured directly from natural wood or from wood blocks made of natural wood.
• the invention can be applied for interior decoration, for covering various wooden structures and in plywood manufacturing.

Landscapes

• Engineering & Computer Science (AREA)
• Life Sciences & Earth Sciences (AREA)
• Wood Science & Technology (AREA)
• Textile Engineering (AREA)
• Manufacturing & Machinery (AREA)
• Mechanical Engineering (AREA)
• Forests & Forestry (AREA)
• Ceramic Engineering (AREA)
• Dry Formation Of Fiberboard And The Like (AREA)
• Laminated Bodies (AREA)

Applications Claiming Priority (2)

Publications (1)

Family

ID=8533581

Family Applications (1)

Country Status (2)

Cited By (3)

Citations (1)

• 1991
  • 1991-11-29 FI FI915635A patent/FI87549C/fi not_active IP Right Cessation
• 1992
  • 1992-11-27 WO PCT/FI1992/000321 patent/WO1993010974A1/en active Application Filing

Patent Citations (1)

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