WO2025111123A1 - Panneaux composites de brins à base de bambou pour applications de construction - Google Patents

Panneaux composites de brins à base de bambou pour applications de construction Download PDF

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Publication number
WO2025111123A1
WO2025111123A1 PCT/US2024/054258 US2024054258W WO2025111123A1 WO 2025111123 A1 WO2025111123 A1 WO 2025111123A1 US 2024054258 W US2024054258 W US 2024054258W WO 2025111123 A1 WO2025111123 A1 WO 2025111123A1
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Prior art keywords
millimeters
bamboo
ranging
rib
panel
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Vikram Yadama
Avishek Chanda
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Washington State University WSU
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Washington State University WSU
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    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
    • E04C2/32—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure formed of corrugated or otherwise indented sheet-like material; composed of such layers with or without layers of flat sheet-like material
    • E04C2/322—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure formed of corrugated or otherwise indented sheet-like material; composed of such layers with or without layers of flat sheet-like material with parallel corrugations
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
    • B27N—MANUFACTURE BY DRY PROCESSES OF ARTICLES, WITH OR WITHOUT ORGANIC BINDING AGENTS, MADE FROM PARTICLES OR FIBRES CONSISTING OF WOOD OR OTHER LIGNOCELLULOSIC OR LIKE ORGANIC MATERIAL
    • B27N3/00—Manufacture of substantially flat articles, e.g. boards, from particles or fibres
    • B27N3/02—Manufacture of substantially flat articles, e.g. boards, from particles or fibres from particles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
    • B27N—MANUFACTURE BY DRY PROCESSES OF ARTICLES, WITH OR WITHOUT ORGANIC BINDING AGENTS, MADE FROM PARTICLES OR FIBRES CONSISTING OF WOOD OR OTHER LIGNOCELLULOSIC OR LIKE ORGANIC MATERIAL
    • B27N3/00—Manufacture of substantially flat articles, e.g. boards, from particles or fibres
    • B27N3/04—Manufacture of substantially flat articles, e.g. boards, from particles or fibres from fibres
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/10—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products
    • E04C2/16—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products of fibres, chips, vegetable stems, or the like
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
    • E04D3/00—Roof covering by making use of flat or curved slabs or stiff sheets
    • E04D3/24—Roof covering by making use of flat or curved slabs or stiff sheets with special cross-section, e.g. with corrugations on both sides, with ribs, flanges, or the like
    • E04D3/32—Roof covering by making use of flat or curved slabs or stiff sheets with special cross-section, e.g. with corrugations on both sides, with ribs, flanges, or the like of plastics, fibrous materials, or asbestos cement

Definitions

  • the present disclosure concerns a corrugated non-woven bamboo composite panel and methods of making and using the corrugated non-woven bamboo composite panel.
  • the corrugated non-woven bamboo composite panel comprises a thickness ranging from 1 millimeter to 10 millimeters; a plurality of top rib spans and bottom rib spans forming a plurality of slopes comprising a rib radius ranging from 5 millimeters to 15 millimeters; a corrugation depth ranging from 5 millimeters to 50 millimeters measured from a lower portion of the lower rib spans to a lower portion of the top rib spans; and a pitch ranging from 50 millimeters to 200 millimeters measured from a center portion of the top rib spans.
  • a corrugated construction panel comprising: a bamboo-based material; a plurality of top rib spans forming a plurality of upward slopes and a plurality of bottom rib spans forming a plurality of downward slopes having a slope angle ranging from 40 degrees to 60 degrees; a thickness ranging from 3 millimeters to 7 millimeters; and a load bearing capacity ranging from 3 N/mm to 5 N/mm.
  • a roofing assembly comprising: a first construction panel, wherein the first construction panel is the corrugated construction panel disclosed herein; and a second construction panel onto the first construction panel, wherein the second construction panel is the corrugated construction panel disclosed herein.
  • a method of making the making a corrugated panel comprising: introducing a bamboo-based material; mixing the bamboo-based material with an adhesive; providing the mixture into a mold comprising a geometry for producing the bamboobased construction panel disclosed herein; and pressing the mixture at a temperature ranging from 280°F to 400°F and under a pressure ranging from 2 MPa to 7 MPa.
  • Also disclosed herein is a method comprising introducing a container having a height ranging from 1015 millimeters to 2035 millimeters; and providing 100 or more of the bamboobased construction panel disclosed herein into the container, wherein the 100 or more bamboobased construction panels are stacked.
  • FIG. 1 A is a schematic drawing showing aspects of the bamboo-based composites disclosed herein comprising a pitch of 120 millimeters, a depth of 35 millimeters, and a slope angle of 51.29°.
  • FIG. IB is a schematic drawing showing aspects of the bamboo-based composites disclosed herein comprising a pitch of 120 millimeters, a depth of 22 millimeters, and a slope angle of 51.29°.
  • FIG. 1C is a schematic drawing showing aspects of the bamboo-based composites disclosed herein comprising a pitch of 150 millimeters, a depth of 35 millimeters, and a slope angle of 51.29°.
  • FIG. ID is a schematic drawing showing aspects of the bamboo-based composites disclosed herein comprising a pitch of 150 millimeters, a depth of 30 millimeters, and a slope angle of 45°.
  • FIG. IE is a schematic drawing showing aspects of the two-dimensional profile of the bamboo-based composites disclosed herein comprising a pitch of 147.99 millimeters, a depth (d) of 30 millimeters, and a slope angle of 45°.
  • FIG. 2A is a schematic drawing showing aspects of the bamboo-based composites disclosed herein comprising a pitch of 80 millimeters, a depth of 20 millimeters, a slope angle of 38.66°, and a flattened length of 1430.89 millimeters.
  • FIG. 2B is a schematic drawing showing aspects of the bamboo-based composites disclosed herein comprising a pitch of 120 millimeters, a depth of 20 millimeters, a slope angle of 29.74°, and a flattened length of 1324.19 millimeters.
  • FIG. 2C is a schematic drawing showing aspects of the bamboo-based composites disclosed herein comprising a pitch of 160 millimeters, a depth of 20 millimeters, a slope angle of 23.96°, and a flattened length of 1280.16 millimeters.
  • FIG. 2D is a schematic drawing showing aspects of the bamboo-based composites disclosed herein comprising a pitch of 80 millimeters, a depth of 27 millimeters, a slope angle of 60.95°, and a flattened length of 1701.8 millimeters.
  • FIG. 2E is a schematic drawing showing aspects of the bamboo-based composites disclosed herein comprising a pitch of 120 millimeters, a depth of 27 millimeters, a slope angle of 47.2", and a flattened length of 1452.88 millimeters.
  • FIG. 2F is a schematic drawing showing aspects of the bamboo-based composites disclosed herein comprising a pitch of 160 millimeters, a depth of 27 millimeters, a slope angle of 22.56°, and a flattened length of 1298.79 millimeters.
  • FIG. 2G is a schematic drawing showing aspects of the bamboo-based composites disclosed herein comprising a pitch of 80 millimeters, a depth of 35 millimeters, a slope angle of 81.87°, and a flattened length of 2147.15 millimeters.
  • FIG. 2H is a schematic drawing showing aspects of the bamboo-based composites disclosed herein comprising a pitch of 120 millimeters, a depth of 35 millimeters, a slope angle of 37.87°, and a flattened length of 1459.65 millimeters.
  • FIG. 21 is a schematic drawing showing aspects of the bamboo-based composites disclosed herein comprising a pitch of 160 millimeters, a depth of 35 millimeters, a slope angle of 32.47°, and a flattened length of 1369.91 millimeters.
  • FIG. 3A is an illustration showing the Ei axis, E2 axis, and E3 axis of the panel in its plan view.
  • FIG. 3B is a linear force versus displacement graph showing the results with respect to the displacement.
  • FIG. 4 is a schematic drawing showing a conventional corrugated profile of a comparator, Indian Standard (IS) 15476, demonstrating decreased stiffness, one dimensional use, minimal bond area, and increased resin content.
  • IS Indian Standard
  • FIG. 5 is a schematic drawing showing aspects of the bamboo-based composites disclosed herein demonstrating a rib radius, depth and pitch for achieving a profile with increased bending stiffness and suitable geometry that is desirable and transferable to the industry.
  • FIG. 6A is a graph showing the signal-to-noise (S/N) ratios calculated for the bending stiffness for different aspects of the depth of the bamboo-based composites disclosed herein.
  • FIG. 6B is a graph showing the signal-to-noise (S/N) ratios calculated for the bending stiffness for different aspects of the pitch of the bamboo-based composites disclosed herein.
  • FIG. 6C is a graph showing the signal-to-noise (S/N) ratios calculated for the bending stiffness for different aspects of the span of the bamboo-based composites disclosed herein.
  • FIG. 6D is a graph showing the signal-to-noise (S/N) ratios calculated for the bending stiffness for different aspects of the rib radius of the hamboo-based composites disclosed herein.
  • FIG. 6E is a bar graph showing the Pareto- ANOV A results on bending stiffness for depth, pitch, rib span, and rib radius of a bamboo-based composite disclosed herein.
  • FIG. 7 is a schematic drawing showing a sandwich structure used for calculating the interlaminar shear strength.
  • FIG. 8 A is a schematic drawing showing aspects of the two-dimensional profile of the bamboo-based composites disclosed herein.
  • FIG. 8B is a schematic drawing showing aspects of the two-dimensional profile of the bamboo-based composites disclosed herein.
  • FIG. 9A is a schematic drawing showing aspects of the two-dimensional profile of the bamboo-based composites disclosed herein.
  • FIG. 9B is a schematic drawing showing aspects of the three-dimensional profile of the bamboo-based composites disclosed herein.
  • FIG. 10A is an image showing aspects of the bamboo-based composites disclosed herein comprising a plurality of transverse ribs.
  • FIG. 10B is a bar graph showing the bond area comparison for a mold having a rib radius of 13.5 millimeters, a mold without transverse ribs, a mold with transverse ribs, and a mold having a rib radius of 10 millimeters.
  • FIG. 11 is a schematic drawing showing the dimensions of the comparator, Indian Standard (IS) 15476.
  • FIG. 12A is bar graph showing the bending stiffness for the comparator (IS); a bamboobased composite disclosed herein comprising a pitch of 120 millimeters, a depth of 35 millimeters, and a slope angle of 51.29°; a bamboo-based composites disclosed herein comprising a pitch of 120 millimeters, a depth of 22 millimeters, and a slope angle of 51.29°; a bamboo-based composites disclosed herein comprising a pitch of 150 millimeters, a depth of 30 millimeters, and a slope angle of 45°; and a bamboo-based composites disclosed herein comprising a pitch of 150 millimeters, a depth of 35 millimeters, and a slope angle of 51.29°.
  • IS comparator
  • FIG. 12B is bar graph showing the interfacial shear stress for the comparator (IS); a bamboo-based composite disclosed herein comprising a pitch of 120 millimeters, a depth of 35 millimeters, and a slope angle of 51.29°; a bamboo-based composites disclosed herein comprising a pitch of 120 millimeters, a depth of 22 millimeters, and a slope angle of 51.29°; a bamboo-based composites disclosed herein comprising a pitch of 150 millimeters, a depth of 30 millimeters, and a slope angle of 45°; and a bamboo-based composites disclosed herein comprising a pitch of 150 millimeters, a depth of 35 millimeters, and a slope angle of 51.29°.
  • IS interfacial shear stress for the comparator
  • FIG. 13 is a schematic drawing showing aspects of a three-dimensional profile of a mold for producing a bamboo-based composite disclosed herein.
  • FIG. 14 is a schematic drawing showing a plurality of bamboo-based composite disclosed herein demonstrating the desirable stacking ability.
  • FIG. 15 A is a schematic drawing showing a roofing assembly comprising the bamboobased composite disclosed herein.
  • FIG. 15B is a schematic drawing showing the single overlap gap and double of the comparator (IS).
  • FIG. 15C is a schematic drawing showing the single overlap gap and double overlap gap of the bamboo-based composite disclosed herein.
  • FIG. 16 is a schematic drawing showing aspects of a three-dimensional profile of a mold for producing a bamboo-based composite disclosed herein.
  • values, procedures, or devices may be referred to as “lowest,” “best,” “minimum,” or the like. It will be appreciated that such descriptions are intended to indicate that a selection among many used functional alternatives can be made, and such selections need not be better, smaller, or otherwise preferable to other selections.
  • a conventional bamboo roofing design used is by cutting open bamboo in half, the nodes within the bamboo culm are removed and cut into adequate sizes, and the resulting bamboo halves are places in an interlocking manner such that one half faces the ground and the other facing the sky.
  • Another structure is a corrugated design, wherein bamboo is provided in sheets configured as a plurality of woven bamboo mats. These mats are then treated with an adhesive resin. A hydraulic press binds the sheets together and gives the sheets an “S” shape.
  • Another design includes thin slices of bamboo woven together in a crossing pattern made to cover a roof.
  • such a geometry has many limitations, including reduced stiffness, one dimensional use, and higher moisture absorption. It is also labor intensive, slower production speeds, expensive and requires undesirably high amounts of resin.
  • bamboo-based composites comprising reduced moisture absorption and desirable geometric parameters designed around depth, pitch, rib span, rib angle, and rib radius that results in a suitable flexural modulus for load bearing capacities and downstream fabrication of sandwich panels with single or multiple 3-D core layers. Also disclosed herein is a mold for producing aspects of the corrugated non-woven bamboo construction panels disclosed herein. Also disclosed herein are aspects of a method of making and using the corrugated non-woven bamboo construction panels disclosed herein. [0058] In some aspects, the bamboo-based composites can include bamboo strand panel geometry in a suitable load carrying system while maintaining a desirable 3-dimensional (3D) profile.
  • the bamboo-based composites comprise a pitch, depth, rib span, and rib radii having suitable parameters for producing a desirable flexural modulus for load bearing capacities.
  • the corrugated non-woven bamboo construction panels comprise a stackable geometry that allows for a greater of number of panels to be stacked for post-production transportation from the manufacturing site and therefore decreases shipping costs.
  • a roofing assembly comprising the corrugated non-woven bamboo construction panels that form gaps for increasing ventilation in housing units.
  • a non-woven bamboo composite panel comprising a wall having a plurality of plurality of upward slopes resulting in a plurality of top rib spans and a plurality of downward slopes resulting in a plurality of lower rib spans, wherein the slopes are arranged with a rib radius.
  • the non-woven bamboo composite panel comprises a depth that measured from a first portion of the wall such as, but not limited to, a bottom portion of the of the lower rib spans) to a second portion of the wall such as, but not limited to, the bottom portion of the top rib spans.
  • the non-woven bamboo composite panel comprises a pitch, which is the distance between a center portion of a top rib span to the center portion of the next top rib span.
  • the non-woven bamboo composite panel comprises a thickness ranging from 1 millimeter to 10 millimeters; a plurality of top rib spans and bottom rib spans forming a plurality of slopes comprising a rib radius ranging from 5 millimeters to 15 millimeters; a depth ranging from 5 millimeters to 50 millimeters measured from a lower portion of the lower rib spans to a lower portion of the top rib spans; and a pitch ranging from 50 millimeters to 200 millimeters measured from a center portion of the top rib spans.
  • the corrugated non-woven bamboo composite panel can have a rib radius ranging from 8 millimeters to 15 millimeters such as from 8 millimeters to 14 millimeters, 8 millimeters to 13 millimeters, 8 millimeters to 12 millimeters, 8 millimeters to 11 millimeters, 8 millimeters to 10 millimeters, or 8 millimeters to 9 millimeters.
  • the corrugated non-woven bamboo composite panel can have a depth ranging from 6 millimeters to 35 millimeters, such as from 8 millimeters to 30 millimeters, 10 millimeters to 30 millimeters, 12 millimeters to 30 millimeters, 14 millimeters to 30 millimeters, 16 millimeters to 30 millimeters, 18 millimeters to 30 millimeters, 20 millimeters to 30 millimeters, 22 millimeters to 30 millimeters, 24 millimeters to 30 millimeters, 26 millimeters to 30 millimeters, or
  • the corrugated non-woven bamboo composite panel can have a pitch ranging from 120 millimeters to 155 millimeters, such as from 125 millimeters to 155 millimeters, 130 millimeters to 155 millimeters, 135 millimeters to 155 millimeters, 140 millimeters to 155 millimeters, 145 millimeters to 155 millimeters, 146 millimeters to 155 millimeters, 147 millimeters to 155 millimeters, 148 millimeters to 155 millimeters, 149 millimeters to 155 millimeters, or 150 millimeters to 155 millimeters.
  • the corrugated non-woven bamboo composite panels comprise top rib spans and bottom rib span having a length ranging from 5 millimeters to 150 millimeters, such as from 10 millimeters to 100 millimeters, 15 millimeters to 100 millimeters, 20 millimeters to 100 millimeters, 25 millimeters to 100 millimeters, 30 millimeters to 100 millimeters, 35 millimeters to 100 millimeters, 40 millimeters to 100 millimeters, 45 millimeters to 100 millimeters, 50 millimeters to 100 millimeters, 55 millimeters to 100 millimeters, 60 millimeters to 100 millimeters, 65 millimeters to 100 millimeters, 70 millimeters to 100 millimeters, 75 millimeters to 100 millimeters, 80 millimeters to 100 millimeters, 85 millimeters to 95 millimeters, or 90 millimeters to 95 millimeters.
  • the corrugated non-woven bamboo composite panel can have a plurality of slopes comprising one or more upward slopes and one or more downward slopes.
  • the one or more upward slopes and one or more downward slopes comprise a slope angle ranging from 40 degrees to 60 degrees.
  • the corrugated non-woven bamboo composite panels can have a slope angle ranging from 42 degrees to 55 degrees such from 44 degrees to 55 degrees, 46 degrees to 55 degrees, 48 degrees to 55 degrees, 50 degrees to 55 degrees, or 52 degrees to 55 degrees.
  • the corrugated non-woven bamboo composite panel can have an overall flattened length ranging from 1400 millimeters to 1600 millimeters such from 1410 millimeters to 1600 millimeters, 1420 millimeters to 1600 millimeters, 1430 millimeters to 1600 millimeters, 1440 millimeters to 1600 millimeters, 1450 millimeters to 1600 millimeters, 1460 millimeters to 1600 millimeters, 1470 millimeters to 1600 millimeters, 1480 millimeters to 1600 millimeters, 1490 millimeters to 1600 millimeters, 1500 millimeters to 1600 millimeters, 1510 millimeters to 1600 millimeters, 1520 millimeters to 1600 millimeters, 1530 millimeters to 1600 millimeters, 1540 millimeters to 1600 millimeters, 1550 millimeters to 1600 millimeters, 1560 millimeters to 1600 millimeters, 1570 mill
  • the corrugated non-woven bamboo composite panel comprises a thickness (t) of 6.35 millimeters, a rib span (s) of 29.6 millimeters, a rib radius (r) of 10 millimeters, a pitch (p) of 120 millimeters, a corrugation depth (d) of 35 millimeters, and a slope angle (a) of 51.29°.
  • the corrugated non-woven bamboo composite panel comprises a thickness (t) of 6.35 millimeters, a rib radius (r) of 10 millimeters, a pitch (p) of 120 millimeters, a rib span (s) of 46.23 millimeters, a corrugation depth (d) of 22 millimeters, and a slope angle (a) of 51.29°.
  • the corrugated non-woven bamboo composite panel comprises a thickness (t) of 6.35 millimeters, a rib radius (r) of 10 millimeters, a pitch (p) of 150 millimeters, a corrugation depth (d) of 35 millimeters, a rib span (s) of 69.82 millimeters, and a slope angle (a) of 51.29°.
  • the corrugated non-woven bamboo composite panel comprises a thickness (t) of 6.35 millimeters, a pitch (p) of 150 millimeters, a corrugation depth (d) of 30 millimeters, and a slope angle (a) of 45°.
  • the corrugated non-woven bamboo composite panel comprises a thickness (t) of 6.35 millimeters, a rib span (s) of 40 millimeters, a rib radius (r) of 8 millimeters, a pitch (p) of 147.99 millimeters, a corrugation depth (d) of 30 millimeters, and a slope angle (a) of 45°.
  • FIGS. 2A-2I are schematic drawings showing aspects of a three-dimensional profile of the corrugated non-woven bamboo composite panels disclosed herein comprising a pitch ranging between 80 millimeters to 160 millimeters, a depth ranging between 20 millimeters and 35 millimeters, a slope angle ranging between 23° and 82°, rib span ranging between 15 millimeters and 35 millimeters, and a flattened length ranging between 1280 millimeters and 2150 millimeters. More specifically, as shown below in Table 1, FIG.
  • FIG. 2A is a schematic drawing showing aspects of the bamboo-based composites disclosed herein comprising a pitch of 80 millimeters, a depth of 20 millimeters, a slope angle of 38.66°, and a flattened length of 1430.89 millimeters.
  • FIG. 2B is a schematic drawing showing aspects of the bamboo-based composites disclosed herein comprising a pitch of 120 millimeters, a depth of 20 millimeters, a slope angle of 29.74°, and a flattened length of 1324.19 millimeters.
  • FIG. 2C is a schematic drawing showing aspects of the bamboo-based composites disclosed herein comprising a pitch of 160 millimeters, a depth of 20 millimeters, a slope angle of 23.96°, and a flattened length of 1280. 16 millimeters.
  • FIG. 2D is a schematic drawing showing aspects of the bamboo-based composites disclosed herein comprising a pitch of 80 millimeters, a depth of 27 millimeters, a slope angle of 60.95°, and a flattened length of 1701.8 millimeters.
  • FIG. 2E is a schematic drawing showing aspects of the bamboo-based composites disclosed herein comprising a pitch of 120 millimeters, a depth of 27 millimeters, a slope angle of 47.2°, and a flattened length of 1452.88 millimeters.
  • FIG. 2F is a schematic drawing showing aspects of the bamboo-based composites disclosed herein comprising a pitch of 160 millimeters, a depth of 27 millimeters, a slope angle of 22.56°, and a flattened length of 1298.79 millimeters.
  • FIG. 2G is a schematic drawing showing aspects of the bamboo-based composites disclosed herein comprising a pitch of 80 millimeters, a depth of 35 millimeters, a slope angle of 81.87°, and a flattened length of 2147.15 millimeters.
  • FIG. 2H is a schematic drawing showing aspects of the bamboo-based composites disclosed herein comprising a pitch of 120 millimeters, a depth of 35 millimeters, a slope angle of 37.87°, and a flattened length of 1459.65 millimeters
  • FIG. 1 is a schematic drawing showing aspects of the bamboo-based composites disclosed herein comprising a pitch of 80 millimeters, a depth of 35 millimeters, a slope angle of 81.87°, and a flattened length of 2147.15 millimeters.
  • FIG. 2H is a schematic drawing showing aspects of the bamboo-based composites disclosed herein comprising a pitch of 120 millimeters, a depth of 35
  • 21 is a schematic drawing showing aspects of the bamboo-based composites disclosed herein comprising a pitch of 160 millimeters, a depth of 35 millimeters, a slope angle of 32.47°, and a flattened length of 1369.91 millimeters.
  • the corrugated non-woven bamboo composite can be a construction panel comprising suitable load bearing capacities.
  • the corrugated construction panel can have a load bearing capacity ranging from greater than 0 N/mm to 10 N/mm such as from 2 N/mm to 7 N/mm, or 3 N/mm to 5 N/mm.
  • the corrugated panel comprises bamboo-based material.
  • the bamboo-based material can have a bending load ranging from 500 N-m to 1000 N-m, such as from 550 N-m to 950 N-m, or 600 N-m to 900 N-m.
  • the bamboo-based material is made from non-woven bamboo strips. In certain aspects, the bamboo-based material is made from non-woven bamboo strands. In particular aspects, the bamboo-based material is made from bamboo fibers. In some aspects, the bamboobased material is made from bamboo particles. In aspects disclosed herein, the bamboo-based material is made from any combination of non-woven bamboo strips, non-woven bamboo strands, bamboo fibers, or bamboo particles. IV. Methods
  • Also disclosed herein is a method of making the corrugated non-woven bamboo composite panel, the method comprising: introducing a bamboo-based material; mixing the bamboo-based material with an adhesive; providing the mixture into a mold comprising a geometry for producing the bamboo-based construction panel; and pressing the mixture at a temperature ranging from 200° F to 500 ° F, such as from 250 0 F to 450 ° F, or 280° F to 400° F and under a pressure ranging from 2 MPa to 7 MPa such as from 2.5 MPa to 5.5 MPa , or 2.75 MPa to 6.2 MPa.
  • the adhesive may comprise polymeric methylene diphenyl diisocyanate (pMDI), phenol formaldehyde (PF), melamine urea formaldehyde (MUF), or any combination thereof.
  • pMDI polymeric methylene diphenyl diisocyanate
  • PF phenol formaldehyde
  • UMF melamine urea formaldehyde
  • a method for assembling construction panels comprising: providing a first construction panel, wherein the first construction panel is the corrugated construction panel disclosed herein; and placing a second construction panel onto the first construction panel, wherein the second construction panel is the corrugated construction panel disclosed herein.
  • the method is for making a roofing assembly comprising the corrugated construction panels disclosed herein.
  • the first construction panel and second construction panel form a single overlap gap ranging from 1 millimeter to 10 millimeters; and a double overlap gap ranging from 5 millimeters to 20 millimeters.
  • the single overlap gap ranges from 2 millimeters to 5 millimeters such as from 2.5 to 4 millimeters, 3 millimeters to 4 millimeters, or 3.5 millimeters to 4 millimeters.
  • the method comprises stacking the bamboo-based construction panel disclosed herein.
  • the method comprises introducing a container having a height ranging from 20 inches to 100 inches; and providing the stacked bamboo-based construction panels disclosed herein into the container.
  • the container comprises a height ranging from 40 inches to 80 inches such as from 40 inches to 70 inches, 40 inches to 60 inches, or 40 inches to 50 inches.
  • the container can be for transporting the bamboo-based construction panels such as, but not limited to, a pallet having a height of 48 inches.
  • 50 or more of the bamboo-based construction panel are provided into the container, 60 or more of the bamboo-based construction panel are provided into the container, 70 or more of the bamboo-based construction panel are provided into the container, 80 or more of the bamboo-based construction panel are provided into the container, 90 or more of the bamboo-based construction panel are provided into the container, 100 or more of the bamboo-based construction panel are provided into the container, 102 or more of the bamboo-based construction panel are provided into the container, 104 or more of the bamboo-based construction panel are provided into the container, 106 or more of the bamboo-based construction panel are provided into the container, 108 or more of the bamboo-based construction panel are provided into the container, 110 or more of the bamboo-based construction panel are provided into the container, 112 or more of the bamboo-based construction panel are provided into the container, 114 or more of the bamboo-based construction panel are provided into the container, 116 or more of the bamboo-based construction panel are provided into the container, 118 or more of the bamboo-based construction panel are provided into the container, 120
  • a corrugated non-woven bamboo composite panel comprising: a thickness ranging from 1 millimeter to 10 millimeters; a plurality of top rib spans and bottom rib spans forming a plurality of slopes comprising a rib radius ranging from 5 millimeters to 15 millimeters; a corrugation depth ranging from 5 millimeters to 50 millimeters measured from a lower portion of the lower rib spans to a lower portion of the top rib spans; and a pitch ranging from 50 millimeters to 200 millimeters measured from a center portion of the top rib spans.
  • the plurality of slopes comprise one or more upward slopes and one or more downward slopes, and wherein the one or more upward slopes and the one or more downward slopes have a slope angle ranging from 40 degrees to 60 degrees.
  • the lower rib spin has a thickness (t), rib span (s), rib radius (r), corrugation depth (d), and pitch (p) according to Equation 1 A
  • the rib radius ranges from 8 millimeters to 15 millimeters; the corrugation depth ranges from 6 millimeters to 35 millimeters; and the pitch ranges from 120 millimeters to 155 millimeters.
  • the plurality of top rib spans and bottom rib spans have a length ranging from 25 millimeters to 95 millimeters.
  • the plurality of top rib spans and the plurality of lower rib spans have a length ranging from 25 millimeters to 95 millimeters; the rib radius ranges from 5 millimeters to 10 millimeters; the corrugation depth ranges from 25 millimeters to 35 millimeters; and the pitch ranges from 145 millimeters to 155 millimeters.
  • the composite panel comprises a flattened length ranging from 1400 millimeters to 1600 millimeters.
  • a corrugated construction panel comprising: a bamboo-based material; a plurality of top rib spans forming a plurality of upward slopes and a plurality of bottom rib spans forming a plurality of downward slopes having a slope angle ranging from 40 degrees to 60 degrees; a thickness ranging from 3 millimeters to 7 millimeters; and a load bearing capacity ranging from 3 N/mm to 5 N/mm.
  • the plurality of top rib spans and bottom rib spans have a length ranging from 35 millimeters to 50 millimeters.
  • the bamboo-based material has a bending load ranging from 600 N-m to 900 N-m.
  • the plurality of upward and downward slopes comprise a rib radius ranging from 5 millimeters to 12 millimeters.
  • the corrugated panel further comprises comprising a corrugation depth ranging from 30 millimeters to 40 millimeters; and a pitch ranging from 120 millimeters to 150 millimeters.
  • a roofing assembly comprising: a first construction panel, wherein the first construction panel is the corrugated construction panel disclosed herein; and a second construction panel onto the first construction panel, wherein the second construction panel is the corrugated construction panel disclosed herein.
  • the first construction panel and second construction panel form a single overlap gap ranging from 1 millimeter to 10 millimeters; and a double overlap gap ranging from 5 millimeters to 20 millimeters.
  • the single overlap gap has a range from between 2 millimeters to 5 millimeters; and the double overlap gap has a range from 10 millimeters to 15 millimeters.
  • a method of making the making a corrugated panel comprising: introducing a bamboo-based material; mixing the bamboo-based material with an adhesive; providing the mixture into a mold comprising a geometry for producing the bamboo- based construction panel disclosed herein; and pressing the mixture at a temperature ranging from 280°F to 400°F and under a pressure ranging from 2 MPa to 7 MPa.
  • the bamboo-based material is made from non-woven bamboo strips, non-woven bamboo strands, bamboo fibers, bamboo particles, or any combination thereof.
  • the adhesive comprises polymeric methylene diphenyl diisocyanate (pMDI), phenol formaldehyde (PF), melamine urea formaldehyde (MUF), or any combination thereof.
  • Also disclosed herein is a method comprising introducing a container having a height ranging from 1015 millimeters to 2035 millimeters; and providing 100 or more of the bamboobased construction panel disclosed herein into the container, wherein the 100 or more bamboobased construction panels are stacked.
  • a numerical analysis package (e.g., Abaqus® CAE) was utilized for establishing the material properties of the bamboo strand materials described in the following examples.
  • Table 2 shows the material properties of the bamboo strands from the investigations conducted on individual strands to achieve the Young’s modulus along the major axis, Ei ; the Poisson’s ratios along the three axes as shown in FIG. 3A, were estimated based on hardwood values known in the art; and the elastic moduli along the other axes were calculated based on Equation 1.
  • Equation 2 The shear modulus, GLR, was further calculated from Equation 2.
  • FIG. 3B is a force-displacement graph of the linear region for each geometric configurations.
  • the results shown in FIG. 3B graph were used to calculate the stiffness of each of the geometric configurations, wherein boundary conditions with displacement being applied on the center and the reaction forces being calculated and plotted with respect to the displacement.
  • a 3 level Analysis e.g., Taguchi analysis
  • an additional analysis e.g., ANOVA Pareto analysis
  • Taguchi Method Includes two aspects: (1) the signal to noise (S/N) ratios, and (2) the orthogonal array, ensuring all the parameters are observed at the same scale level. In short, it helps in developing a graphical study of the significant factors via the S/N ratio analysis. In addition, the Pareto-analysis of variance (ANOVA) is used for determining the contribution of each parameter in terms of the quantitative value. Thress of the methods in which Taguchi Analysis can be conducted include “smaller-is-better” for minimizing the response; “larger-is -better” for maximizing the response; and “nominal-is-best” for an average value response.
  • S/N signal to noise
  • ANOVA Pareto-analysis of variance
  • the stiffness maximization was investigated by modifying the geometry for the current third generation (e.g., Gen-3) panels, as disclosed herein.
  • the second generation (e.g., Gen-2) panels were the ones made in Phase I of the project.
  • the various panel geometry parameters were investigated to produce a profile exhibiting desirable bending stiffness while maintaining a suitable geometry for the forming process that is transferable to the industry.
  • the “Larger-is-better” policy was used for investigating the S/N ratios, noise or variabilities of the selected factors and their three levels.
  • the “Larger-is-better” method was utilized in the current example but the other two methods can be utilized.
  • the selection of values representing the factors for achieving a suitable range and the respective levels are shown in Table 3, which were used to develop the L9 design matrix for performing the 3-level Taguchi analysis.
  • FIGS. 6A-6D The corresponding S/N ratios were plotted and are shown in FIGS. 6A-6D.
  • FIG. 6A shows the depth of the corrugated panel
  • FIG. 6B shows the pitch of the corrugations
  • FIG. 6C shows the rib span of the corrugated profile
  • FIG. 6D shows the rib radius of the spans.
  • FIGS. 6A-6D demonstrate that the stiffness is greater when the depth is highest at 35 mm, the pitch is lowest at 80 mm, the rib span is highest at 35 mm, and the rib radius is at 13.5 mm. The variation in noise can also be observed to be the highest for the depth of the panels, while pitch, rib span and rib radius have low variations.
  • FIG. 6E demonstrates that the influence of depth is the highest at 83.8%; the pitch and rib span had similar influence of 7.5% and 8.5%, respectively; and the rib radius had minimal influence.
  • the change in rib radius did not influence the stiffness of the panel and the change in the pitch had minimal influence on the stiffness.
  • FIG. 4 is a schematic drawing showing the comparator, which includes a geometry as per the current (IS). As previously discussed, such a profile has many limitations, including reduced stiffness, one dimensional use due to minimal bond area for sandwich structures, and higher resin content. In contrast to the comparator, this example demonstrates desirable geometric parameters such as, but not limited to, the pitch varying between 80 mm and 160 mm, depth varying between 20 mm and 35 mm, rib span varying between 10 mm and 35 mm, and rib radius varying between 8 mm and 17.25 mm.
  • Equation 4 Equation 4
  • V the reaction force from bending loads
  • El the stiffness of the assembly
  • E/ the Young’s modulus of the face-sheet
  • tf the thickness of the face-sheet
  • d the total thickness of face- sheet and the height of the core (t c ).
  • WS panels which are thin-walled hollow-core wood strand sandwich panels.
  • the peak force under bending for the wood-strand sandwich panels was considered as V for calculating the interfacial shear strength of the panel.
  • the calculated interfacial shear stress was 0.16 MPa and was further used as the interfacial shear stress of the new sandwich structure, using which the maximum load was back calculated to understand the load bearing capacities.
  • the load bearing capacities of the WS panels was 3.8 kN, which was calculated to be 3.1 kN for the new panels.
  • Experimental values were used to calculate the interfacial shear stress of the WS panels, with actual slopes. The following factors were also considered: bamboo’s greater stiffness relative to wood; the influence of the bond area of the established WS panels; and the thickness of the core panels (50% of the amount of used in the WS sandwich panels).
  • FIG. 8 is a schematic drawing showing aspects of the two-dimensional profile of the panel comprising the parameters determined above.
  • the pitch was increased to 120 mm to achieve a more desirable slope angle that could be easily formed.
  • the updated 2-dimensional drawing is illustrated in FIG. 9A, along with the 3- dimensional corrugated profile shown in FIG. 9B.
  • the first generation (e.g., GEN- 1) panels were made from woven bamboo strips, whereas the current third generation (e.g., GEN-3) panels are to be made from bamboo strands.
  • the panels provided in the comparator (IS), are 3.8 mm thick, which was possible because three layers of woven bamboo mats were used.
  • the thickness of the panels was increased to 6.35 mm (0.25 inch).
  • the strand thickness was also reduced to have a thickness ranging from 0.01” to 0.02”, or 0.25 mm to 0.5 mm.
  • FIG. 10A is an image of a second generation (e.g., GEN-2) panel comprising a transverse rib along with the longitudinal ribs.
  • the bond area of the GEN-2 panel comprising a transverse rib was compared to a panel with no transverse rib.
  • FIG. 10B is a bar graph showing the GEN-2 panel comprising a transverse rib bond area of 1266 in 2 (0.82 m 2 ) and the GEN-2 panel without a transverse rib having a bond area of 691 in 2 (0.45 m 2 ).
  • the overall bond area was calculated to be almost two-fold.
  • the rib radius was decreased to 10 mm to increase the bond area, which is referred to as the E-Panel. Accordingly, the total bond area increased by 50%, 1033 in 2 (0.7 m 2 ) compared to 0.82 m 2 of the second generation (e.g., GEN-2) panel as demonstrated in FIG. 10B.
  • FIGS. 1 A-1D are schematic drawing showing the dimensions of the comparator, Indian Standard 15476 (IS Panel).
  • FIG. 1A is a schematic drawing showing aspects of the bamboo-based composites disclosed herein (Model-0/M-0) comprising a pitch of 120 millimeters, a depth of 35 millimeters, and a slope angle of 51.29°.
  • FIG. 1A is a schematic drawing showing aspects of the bamboo-based composites disclosed herein (Model-0/M-0) comprising a pitch of 120 millimeters, a depth of 35 millimeters, and a slope angle of 51.29°.
  • IB is a schematic drawing showing aspects of the bamboo-based composites disclosed herein comprising a pitch of 120 millimeters, a depth of 22 millimeters, and a slope angle of 51.29° (Model- 1/M- 1).
  • FIG. 1C is a schematic drawing showing aspects of the bamboo-based composites disclosed herein comprising a pitch of 150 millimeters, a depth of 30 millimeters, and a slope angle of 51.29° (Model-2/M-2).
  • FIG. ID is a schematic drawing showing aspects of the bamboo-based composites disclosed herein comprising a pitch of 150 millimeters, a depth of 35 millimeters, and a slope angle of 45° (Model- 3/M-3).
  • FIGS. 12A-12B Flexural analysis was again performed in Abaqus®, and the comparisons between the designs are provided in FIGS. 12A-12B.
  • the bending stiffness comparison shown in FIGS. 12A- 12B demonstrates that although M-0 had the highest value, M-3 exhibited a desirable performance, exhibiting an 185% higher stiffness relative to the IS panel and about 25% lower stiffness than M- 0.
  • the interfacial shear stress comparison shows that the IS-panel had the highest stress concentration, followed by M-3, and the lowest in M-0.
  • the interfacial shear stress was 170% lower than the IS-panel and only about 19% higher than the previously obtained design, M-0.
  • the bond area was recalculated for the sandwich panels.
  • the M-3 design was calculated to have a bond area of 1067.5 in 2 (0.69 m 2 ), which was about 3% higher than the E-panel but about 16% less than the Gen-2 panels.
  • the rib radius was reduced to 8 mm as illustrated by the schematic drawing shown in FIG. IE (Model-4/M-4), which increased the bond area to 1209 in 2 or 0.8 m 2 .
  • Model-4 had the greatest bond area relative to the other models investigated and 4.5% lower than the Gen-2 panels.
  • Numerical analysis with the aid of Abaqus® was further performed to investigate the change in stiffness and interfacial shear stresses. The results demonstrate that M-4 had a 1.2% in bending stiffness decrease and a 1.2% increase in interfacial shear stress.
  • FIG. 13 is an illustration of the 3-D panel used to manufacture the mold with the third generation (e.g., GEN-3) panel geometric parameters comprising a depth a depth of 30 mm; a pitch of 150 mm; a rib span of 46.63 mm (corner to corner) and 40 mm (flat); and a rib radius of 8 mm.
  • the third generation e.g., GEN-3 panel geometric parameters comprising a depth a depth of 30 mm; a pitch of 150 mm; a rib span of 46.63 mm (corner to corner) and 40 mm (flat); and a rib radius of 8 mm.
  • the panels had a height of 6 inches or 152.5 millimeters and are to be generally shipped in pallets.
  • the conventional packing height is 48 inches (1219.2 millimeters), which leaves about 42 inches (1066.8 millimeters) for the product and therefore 116 of the panels can be shipped together on a pallet, more than M-0.
  • the parameters therefore increased by 8.98 ⁇ 0.13 millimeters (0.3535 ⁇ 0.01 inches) per panel during stacking.
  • the roofing assembly of the third-generation bamboo roofing panels are shown in FIG.
  • FIG. 15A shows that the overlap gaps between the panels provide additional ventilation to the building, which are desirable in low-income housing units.
  • FIG. 15B shows that the minimum gap achieved from a single overlap was 2.6 mm and the maximum gap achieved from a double overlap was 11.6 mm. These were then compared to Indian Standard panels, as illustrated in FIG. 15C.
  • the single overlap gap in the Indian sinusoidal panels was 1.92 mm and the double overlap gap was 10.18 mm. As such, the 14% increase and 1.4 mm increase in gaps of the panels disclosed herein was desirable.
  • FIG. 16 is a schematic drawing showing a mold assembly for producing GEN-3 panels comprising a depth of 30 mm, pitch of 150 mm, rib span of 40 mm (flat), and rib radius of 8 mm. The thickness of the panels was 6.35 mm, to produce stiffer and high utility panel fabrication.

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  • Life Sciences & Earth Sciences (AREA)
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  • Manufacturing & Machinery (AREA)
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Abstract

L'invention concerne des aspects d'un panneau composite non tissé ondulé en bambou présentant un pas, une profondeur, une portée de nervures et des rayons de nervures dans des paramètres permettant d'augmenter les capacités porteuses de charge. L'invention concerne également un procédé de fabrication et d'utilisation du panneau composite non tissé ondulé en bambou divulgué ici. Dans certains aspects, les panneaux composites non tissés en bambou divulgués ici ont une capacité d'empilement permettant le transport et forment des espaces souhaitables entre les panneaux pendant l'assemblage d'un toit.
PCT/US2024/054258 2023-11-02 2024-11-01 Panneaux composites de brins à base de bambou pour applications de construction Pending WO2025111123A1 (fr)

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Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2070401A (en) * 1935-01-09 1937-02-09 Carey Philip Mfg Co Corrugated sheathing
BE643846A (fr) * 1963-02-21 1964-08-14
DE4020682A1 (de) * 1989-01-20 1992-01-02 Darma Joseph Verfahren zur effektiven nutzung von bambus im bauwesen und als werkstoff
FR2698394A3 (fr) * 1992-05-19 1994-05-27 Nuova Sacelit Spa Plaque ondulée utilisable dans la construction.
EP0765738A1 (fr) * 1995-04-12 1997-04-02 Onnetsu Kankyo Kaihatsu Inc. Article stratifie ou moule et procede pour le fabriquer
US20090166912A1 (en) * 2007-12-27 2009-07-02 Seong Hoon Han Method for manufacturing construction materials by using palm
US8475894B2 (en) * 2008-03-28 2013-07-02 Nobel Environmental Technologies Corp. Engineered molded fiberboard panels, methods of making the panels, and products fabricated from the panels
US10167636B2 (en) * 2014-06-26 2019-01-01 Onduline Method of designing a corrugated sheet and corregated sheet obtained

Patent Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2070401A (en) * 1935-01-09 1937-02-09 Carey Philip Mfg Co Corrugated sheathing
BE643846A (fr) * 1963-02-21 1964-08-14
DE4020682A1 (de) * 1989-01-20 1992-01-02 Darma Joseph Verfahren zur effektiven nutzung von bambus im bauwesen und als werkstoff
FR2698394A3 (fr) * 1992-05-19 1994-05-27 Nuova Sacelit Spa Plaque ondulée utilisable dans la construction.
EP0765738A1 (fr) * 1995-04-12 1997-04-02 Onnetsu Kankyo Kaihatsu Inc. Article stratifie ou moule et procede pour le fabriquer
US20090166912A1 (en) * 2007-12-27 2009-07-02 Seong Hoon Han Method for manufacturing construction materials by using palm
US8475894B2 (en) * 2008-03-28 2013-07-02 Nobel Environmental Technologies Corp. Engineered molded fiberboard panels, methods of making the panels, and products fabricated from the panels
US10167636B2 (en) * 2014-06-26 2019-01-01 Onduline Method of designing a corrugated sheet and corregated sheet obtained

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