Lightweight Wood-Based Composite Panel and Method for Its Manufacture

Simple SummaryContent extracted from patent full text and abstract with AI.

This patent describes a method for manufacturing a lightweight engineered wood sandwich panel consisting of two highly compacted outer wood layers (cover layers) and a foamed, low-density intermediate layer. The key innovation is that the outer layers are compacted before the foaming of the intermediate layer begins, allowing much higher density and strength in the surface layers than previous single-step methods. The foamed layer is produced by thermal activation, and the entire panel achieves an optimal strength-to-weight ratio while being produced in a cost-effective and efficient process.

Use CasesContent extracted from patent full text and abstract with AI.

• Furniture manufacturing, including tables, cabinets, and shelving where light weight and strength are desired.
• Interior construction materials such as wall panels, doors, and partitions.
• Caravan, mobile home, or yacht interior fitting for lightweight but sturdy construction elements.
• Automotive or transport industry for non-structural, lightweight interior panels.
• Building or refurbishment of exhibition stands, shopfitting, or modular spaces.

BenefitsContent extracted from patent full text and abstract with AI.

• Significantly improved strength-to-weight ratio compared to conventional engineered wood panels.
• Lower raw material usage and production costs due to reduced material requirements for the same functionality.
• Higher surface hardness and durability due to highly compacted cover layers.
• Improved mechanical properties, including load capacity and resistance to bending or breakage.
• Enables continuous, large-scale, and cost-effective manufacturing processes.
• Reduces dust and health risks associated with handling of particulate foamable materials.
• Allows fine control over the physical and mechanical properties of both the surface and core of the panel, enabling a broad range of tailored applications.

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Inventors & Applicants

Patent Abstract

The invention relates to a process for producing a sandwich board, comprising the following steps: providing an upper covering layer, providing a lower covering layer, providing an intermediate layer arranged between the upper and lower covering layers, compressing the upper and lower covering layers, and foaming the intermediate layer, in which process no foaming of the intermediate layer takes place at the start of compacting the upper and lower covering layers.