METHOD FOR PRODUCING CROSS-LAMINATED TIMBER PANELS WITH CUTOUTS AND WOODEN PANEL PRODUCTION DEVICE

Abstract

A device for joining multi-layered panels made of individual boards has a height-adjustable workbench. layers of boards arranged at an angle to each other and joined together. A guide for the material is provided at least on one side of the workbench, preferably on two adjoining sides. The device comprises at least one transport device for transporting boards to the processing position.

Claims

1. A method for producing cross-laminated timber panels with cutouts, wherein the cross-laminated timber panels are constructed of at least one longitudinal layer of boards that are arranged in rows (parallel to each other in a longitudinal direction, and at least one transverse layer of boards that are arranged in rows (parallel to each other in a transverse direction, comprising the steps a) dividing the boards in rows in which the cutouts are located into individual boards to create the cutouts in the at least one longitudinal layer; b) laying the individual boards to form a first longitudinal layer; c) gluing the individual boards together on longitudinal sides of each of the individual boards; wherein both the longitudinal layer of boards and the transverse layer of boards are produced in a same joining station; d) forming a second longitudinal layer from a plurality of individual boards in multiple rows, wherein in several rows individual boards are laid and glued together on longitudinal sides of individual boards of the plurality of individual boards so as to allow for cutouts, wherein the second longitudinal layer is stepped in the transverse direction, wherein an area of the second longitudinal layer corresponds to an area of the first longitudinal layer without the cutouts; e) dividing the second longitudinal layer into at least two partial panels, f) rotating the at least two partial panels are by 90; g) laying the at least two partial panels rotated by 90 together to form the transverse layer, and joining the at least two partial panels together such that the cutouts are formed during joining; and h) laying the transverse layer on the longitudinal layer as overlapping layers, and gluing together the overlapping layers.

2. The method according to claim 1, further comprising arranging an insulating panel between each of the individual boards of the transverse layer.

3. The method according to claim 2, further comprising using a board to bound lateral edges running in the transverse direction of the transverse layer.

4. The method according to claim 1 wherein at least one row of the rows formed by the dividing step contains a maximum of five individual boards.

5. The method according to claim 1 further comprising transporting the individual boards to a joining station in the longitudinal direction; positioning the individual boards at the joining station using adjustable end stops; and, following positioning, introducing the individual boards into the joining station in the transverse direction.

6. The method according to claim 1 further comprising trimming lateral edges of both the first longitudinal layer and the second longitudinal layer as cross-laminated timber panels before further processing for calibration.

7. The method according to claim 3 wherein the insulating panels are wider than the individual boards.

8. A wooden panel production device for producing cross-laminated timber panels with cutouts, wherein the cross-laminated timber panels are constructed of at least one longitudinal layer of boards that are arranged in rows (parallel to each other in a longitudinal direction, and at least one transverse layer of boards that are arranged in rows parallel to each other in a transverse direction, comprising: a cut-off device configured to divide the boards in rows, in which cutouts are located, into individual boards to produce the cutouts in the at least one longitudinal layer; a glueing device configured to glue longitudinal sides of the boards; a joining station for laying and pressing the boards to create a first longitudinal layer, wherein the cut-off device is configured to divide a second longitudinal layer stepped in the transverse direction, wherein an area of the second longitudinal layer corresponds to an area of the first longitudinal layer without the cutouts, and wherein the cut-off device is used to form at least two partial panels; a rotation device configured to rotate the at least two partial panels by 90, wherein the joining station configured to lay the at least two partial panels rotated by 90 together to form the transverse layer and join them together such that the cutouts are also formed; and a joining device configured to place the transverse layer on the longitudinal layer as overlapping layers, and to glue the overlapping layers together.

9. The wooden panel production device according to claim 8, further comprising a joining device configured to place the transverse layer on the longitudinal layer as overlapping layers, and to glue the overlapping layers together.

10. The wooden panel production device according to claim 9, wherein the joining station comprises the joining device.

11. The wooden panel production device according to claim 8 further comprising a longitudinal layer formation device configured to form the second longitudinal layer from a plurality of individual boards in multiple rows in order to create cutouts, wherein individual boards are laid in several rows and glued together on longitudinal sides of the individual boards to allow for the cutouts, wherein the second longitudinal layer is stepped in the transverse direction R.sub.Q, and wherein an area of the second longitudinal layer corresponds to an area of the first longitudinal layer without the cutouts.

12. The wooden panel production device according to claim 8, further comprising: a transport device configured to transport the boards to the joining station in the longitudinal direction; adjustable end stops for positioning the boards; and a pushing device configured to introduce the boards (into the joining station in the transverse direction after positioning.

13. The wooden panel production device according to claim 8 further comprising a trimming device configured to trim the cross-laminated timber panels before further processing so as to calibrate the cross-laminated timber panels.

14. The wooden panel production device according to claim 8 wherein the joining station is configured to arrange an insulating panel between each of the boards for the transverse layer.

15. The wooden panel production device according to claim 8 wherein a separating device is configured to control the glueing device, the joining station, the rotation device, and the joining device so that the wooden panel production device automatically performs a method of producing cross-laminated timber panels.

Description

DESCRIPTION OF THE DRAWINGS

[0038] In the following, an embodiment example of the invention will be explained in more detail with the aid of accompanying figures. They show:

[0039] FIG. 1 is a longitudinal layer for a cross-laminated timber panel;

[0040] FIG. 2 is a transverse layer for a wood-based material panel;

[0041] FIG. 3a is the schematic representation of the arrangement of the boards in a second longitudinal layer to form a transverse layer and the processing steps involved;

[0042] FIG. 3b is the schematic representation of the arrangement of the boards in a second longitudinal layer to form a transverse layer and the processing steps involved;

[0043] FIG. 4 is the schematic representation of the process for joining the boards;

[0044] FIG. 5 shows the positioning of five boards of varying length and position in a path-time diagram; and

[0045] FIG. 6 is a schematic representation of the positioning of the boards in the joining station.

DESCRIPTION

[0046] FIG. 1 shows a longitudinal layer composed of a plurality of boards L.sub.1, L.sub.2, . . . L.sub.i, . . . L.sub.21, L.sub.22, which are arranged in rows I, II, III, IV, . . . X and glued together. A cutout A.sub.1 for a window and a cutout A.sub.2 for a door are provided in the longitudinal layer L. FIG. 4 corresponds to the representation according to FIG. 1 and demonstrates that the first uncut board L.sub.1 is first introduced into the joining system and moved forward until the end stop 1.

[0047] The second uncut board L.sub.2 is then coated with glue, especially a hot melt adhesive, on the longitudinal edge facing the first board L.sub.1, introduced into the joining system 1, transported up to the end stop 1, and then pushed in the transverse direction R.sub.Q against the first board L.sub.1 and pressed with it. The contact between the hot melt adhesive and the longitudinal edge of the first board L.sub.1 causes the former to cure quickly, fixing the two boards L.sub.1, L.sub.2 together.

[0048] To begin the window cutout A.sub.1, the next board L.sub.3 is designed to be shorter. It is glued on its lateral side facing the second board L.sub.2, transported into the joining system up to the end stop 1, then pushed in the transverse direction R.sub.Q against the second board L.sub.2 and joined to it using the hot melt adhesive.

[0049] The fourth board L.sub.4 is designed to be even shorter and, after first being glued on its lateral edge facing the third board L.sub.3, is transported into the joining system up to the end stop 3 and then pushed in the transverse direction R.sub.Q against the board L.sub.2 and joined to it. Accordingly, the next cut boards L.sub.5, L.sub.6, up to L.sub.21 and L.sub.22, are glued in order to form the first part of the door cutout A.sub.2, 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 L.sub.1. This produces a longitudinal length L.

[0050] For practicality, the boards L.sub.i 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 L.sub.5 is initially transported against end stop 1, board L.sub.6 against end stop 2 and board L.sub.7 against end stop 3, then all three boards L.sub.5, L.sub.6, L.sub.7 are pushed together against the boards L.sub.3 and L.sub.4 previously joined in row III and pressed in order to fix them (see FIG. 4). The end stops 1, 2 and 3 are arranged such that they can be moved in the longitudinal direction R.sub.L in order to achieve high variability for the cutouts A.sub.1, A.sub.2 to be introduced. Additional end stops can be provided if further cutouts A.sub.1 are desired.

[0051] 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 A.sub.1 and A.sub.2 must of course be in the same location.

[0052] The door cutout A.sub.2 may render the cross-laminated timber panel unstable during transport to the construction site. To avoid breaking or tearing, boards L.sub.21 and L.sub.22 could be made as a single long board the door cutout then completed by cutting this last board once at the construction site.

[0053] The transverse layer Q to be glued to the longitudinal layer L can be seen in FIG. 2. Boards Q.sub.1, Q.sub.2, Q.sub.3, . . . Q.sub.1 . . . Q.sub.6, Q.sub.7, Q.sub.8 are glued together with their longitudinal axis parallel to the transverse direction R.sub.Q. Due to the alignment of boards Q.sub.1, the transverse layer Q cannot be produced immediately in the same joining system as the longitudinal layer L, which is clearly demonstrated when comparing FIGS. 1 and 2, as the boards have to be guided in different directions.

[0054] How the transverse layer Q is produced is shown in FIGS. 3a and 3b (starting at the bottom right and ending at the top right), which, one after the other, illustrate the production process. FIGS. 3a and 3a are identical. They simply show different reference signs so as to improve clarity.

[0055] First, a second longitudinal layer LZ is produced in a longitudinal layer formation device, not depicted, with boards B.sub.i, which are aligned with their longitudinal axes in the longitudinal direction R.sub.L. 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.

[0056] The three upper boards B.sub.1, B.sub.2, B.sub.3 in rows I, II, III extend across the entire length. Conversely, boards B.sub.4 to B.sub.11 in rows IV, V, VI are designed to be shorter, resulting in a stepped panel in the longitudinal direction R.sub.L.

[0057] 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 A.sub.1, A.sub.2. The size of panels B and C and E can be calculated from the size of the cutouts A.sub.1, A.sub.2 to be produced. The size of panels A, D and F can also be calculated. Correspondingly, boards B.sub.1, B.sub.2, . . . B.sub.1, . . . B.sub.10, B.sub.11 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.

[0058] 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 R.sub.Q 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 R.sub.Q 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 R.sub.Q if necessary and joined to the already positioned partial panel with the glued lateral edge.

[0059] As can be seen in the lower illustrations in FIG. 3, the partial panels B/C are not divided, but are jointly rotated by 90 and then transported in the transverse direction R.sub.Q. Since these two partial panels B, C are too small, it makes more sense not to cut them until after being rotated by 90 and then to position them against end stops 104, 105 in order to form the lintel (partial panel C) and the sill (partial panel B) of window cutout A.sub.1. The end result is the representation of the transverse layer Q, as shown in the top right of FIG. 3a. Eleven boards B.sub.i, which were laid and glued to the second longitudinal layer LZ, become 28 boards (Q.sub.1, Q.sub.2, . . . Q.sub.28) in the transverse layer Q due to the multiple division.

[0060] FIG. 3b corresponds to FIG. 3a, in which only the reference signs for the individual boards B.sub.i or Q.sub.i have been eliminated. This transverse layer Q created from the second longitudinal layer LZ is then gripped, the first longitudinal layer LE is coated with wood glue on its upper side and the two wooden panels, longitudinal layer L and transverse layer Q, are pressed together by the joining device until the wood glue has hardened and the cross-laminated timber panel is produced. For example, the joining station 200 can comprise the joining device, which is configured to place the transverse layer Q on the longitudinal layer L and to glue the superimposed layers together.

[0061] 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 L.sub.i, Q.sub.i of the adjoining panels cross each other.

[0062] FIG. 4 illustrates that a planed slat of multiple lengths, i.e. a length that can exceed the maximum length of a board L.sub.i, is first fed into a finger-jointing line. A cut-off device 150, for example in the form of a chop saw, then cuts the first board L.sub.1 to the desired length from this planed slat. This board is then transported in the transverse direction R.sub.Q and then moved in the longitudinal direction R.sub.L against the end stop 1 The left-hand illustration of individual boards shows the sequence required to join the longitudinal layer L of the wooden panel.

[0063] The functional sequence for joining the boards L.sub.1, L.sub.2, . . . L.sub.i . . . L.sub.22 is described below with reference to FIG. 6. The boards required for a joining plane are available cut to length in a buffer not shown here. They are accelerated to approximately 180 m/min in the longitudinal direction with a mangle, not shown, and guided through a side gluing process on an edge with hot melt adhesive. They then continue at, for example, 180 m/min over a 16.5 m long transport device 100, for example in the form of a roller conveyor with rollers 101. The rollers 101 are set at an angle and a width-adjustable ruler 102 is provided at the rear of the joining station P. The transport device 100 is divided into fifteen individually driven sections, as shown schematically in FIG. 6.

[0064] 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.

[0065] The diagram in FIG. 5 shows the positioning of five boards of different lengths and positions. The distance is plotted on the ordinate axis and the time on the abscissa. The solid line represents the front edge of a board, the dashed line below it is the rear edge of a board, and the vertical distance between the lines corresponds to the length of a board. At a running speed of 180 m/min, all boards are in their joining position after 9.8 seconds. The slats run through the joining station 200 with an offset of around 1 s (equivalent to 3.0 m) between the rear edge of the leading board and the front edge of the following board.

[0066] 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 L.sub.i. 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.

[0067] As can be seen in the path-time diagram in FIG. 5, several boards are travelling at the same time. If there is a large gap, end stop 3 catches its board before end stop 2 catches its board. If an end stop is deactivated (for a continuous board that forms the lintel above cutout A.sub.1, for example), the count changes. If end stop 4 is deactivated, end stop 5 lets three boards through. If end stop 2 is deactivated, end stop 3 only allows one board through, end stop 4 two and end stop 5 three.

[0068] 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 FIG. 6). When retracting, the side pushers 103 lower below the roller level. The following boards can then immediately enter again and are guided along the ruler 102, which can be adjusted to the width of the board. This ruler 102 is slotted to pass through the side pushers 103.

[0069] 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.

[0070] 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.

[0071] 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.

[0072] Only the immediately preceding board (A.sub.i, B.sub.i) 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 A.sub.1, A.sub.2, they must not exert any counter-pressure so that the section behind can continue to move freely (see FIG. 6). A sensor on the counter-pressure unit recognizes whether the position is occupied by a board or not. Pressure is only built up in the first case. The following board (L.sub.i+1, B.sub.i+1) then pushes through the preceding board (L.sub.i+1, B.sub.i+1) and is itself held in the clamping device from above, pressing on the sliding base.

[0073] 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.

[0074] The insulating boards can be wider than the boards for the longitudinal layers L.sub.i or the transverse layers Q.sub.1. 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.

[0075] 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 B.sub.i) 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.

[0076] These rectangles are rotated by 90 and placed next to each other, resulting in the total length of the first board B.sub.1. The required lengths and positions of boards B.sub.2 to B.sub.11 are then calculated accordingly (FIG. 3a).

REFERENCE LIST

[0077] 100 transport device, roller conveyor [0078] 101 rollers [0079] 102 ruler [0080] 103 pushing device, side pusher [0081] 104 end stop [0082] 105 end stop [0083] 150 cut-off device, chop saw [0084] 160 glueing device [0085] 170 rotation device [0086] 180 control device [0087] 200 joining station [0088] A.sub.1, A.sub.2 cutout [0089] B.sub.1, B.sub.2, . . . B.sub.i, . . . B.sub.10, B.sub.11 board [0090] L.sub.1, L.sub.2, . . . L.sub.i . . . L.sub.1, L.sub.11 board [0091] L longitudinal layer [0092] LE first longitudinal layer [0093] LZ second longitudinal layer [0094] I, II, III, IV, . . . X row [0095] Q transverse layer [0096] Q.sub.1, Q.sub.2, Q.sub.3, . . . Q.sub.i, . . . Q.sub.23, Q.sub.24, Q.sub.25 board [0097] R.sub.L longitudinal direction [0098] R.sub.Q transverse direction [0099] A, B, C, D, E, F partial panels