Core layer comprising zigzag-shaped wood elements and multilayer composite comprising the core layer

Abstract

A core layer, a multilayer composite, and methods of making and using the same are provided. The core layer includes wooden zigzag-shaped elements and is suitable for producing a multilayer composite, or for use in a multilayer composite. The multilayer composite includes at least one cover layer and a core layer, and the cover layer is arranged such that it at least partially covers the core layer and is fixedly connected to the core layer.

What is claimed is: 
     
         1 . A core layer comprising:
 a plurality of wooden zigzag-shaped elements each comprising zigzagging laminar regions, wherein a zig region of a given element and an adjoining zag region of the given element form between them a common edge;   wherein the plurality of zigzag-shaped elements are arranged such that a common edge of a first zigzag-shaped element and a common edge of a second zigzag-shaped element intersect at an angle which is different from zero; and   wherein the first zigzag-shaped element and the second zigzag-shaped element are fixedly connected to each other at at least one point of intersection.   
     
     
         2 . The core layer according to  claim 1 , wherein the plurality of wooden zigzag-shaped elements each comprise repeating units of zig and zag regions, and wherein the common edges formed between the zig and zag regions within a given element run parallel to one another. 
     
     
         3 . The core layer according to  claim 1 , wherein the plurality of zigzag-shaped wood elements further comprise fibres having a preferred direction, and wherein the common edge runs non-parallel to the preferred direction within a given element. 
     
     
         4 . The core layer according to  claim 3 , wherein the common edge runs perpendicular to the preferred direction of the fibres within a given element. 
     
     
         5 . The core layer according to  claim 1 , wherein the common edge has been produced by one of folding or cutting. 
     
     
         6 . The core layer according to  claim 3 , wherein a length of the fibres within a given element is at least twice as long as a thickness of a zig or zag region within the given element. 
     
     
         7 . The core layer according to  claim 1 , wherein a thickness of a zig or zag region lies in the range from 0.2 mm to 2 mm, a height of a wooden zigzag-shaped element lies in the range from 0.8 mm to 8 mm, and a length of the common edge lies in the range from 0.5 cm to 10 cm. 
     
     
         8 . The core layer according to  claim 1 , wherein the core layer has a thickness, and a height of each zig or zag region measures no more than one-tenth of the thickness of the core layer. 
     
     
         9 . The core layer according to  claim 1 , wherein each wooden zigzag-shaped element is bonded to a planar element such that one or more cavities are formed between the wooden zigzag-shaped elements and the planar element. 
     
     
         10 . The core layer according to  claim 1 , wherein at least one wooden zigzag-shaped element is bonded to a planar element such that one or more cavities are formed between the wooden zigzag-shaped element and the planar element. 
     
     
         11 . The core layer according to  claim 1 , wherein at least one wooden zigzag-shaped element is bonded to two planar elements such that a plurality of cavities is formed between the wooden zigzag-shaped element and the two planar elements, and wherein the wooden zigzag-shaped element is surrounded in a sandwich-like manner by the two planar elements. 
     
     
         12 . The core layer according to  claim 1 , wherein the core layer comprises at least one element comprising two wooden zigzag-shaped elements bonded to a planar element such that a plurality of cavities is formed between the two wooden zigzag-shaped elements and the planar element, and wherein the planar element is surrounded in a sandwich-like manner by the two wooden zigzag-shaped elements. 
     
     
         13 . A method of producing a core layer, the method comprising:
 (i) providing wooden zigzag-shaped elements each comprising zigzagging laminar regions, wherein a zig region of a given element and an adjoining zag region of the given element form between them a common edge;   (ii) arranging the wooden zigzag-shaped elements such that a common edge of a first zigzag-shaped element and a common edge of a second zigzag-shaped element intersect at at least one point of intersection and at an angle which is different from zero; and   (iii) fixedly connecting the common edge of the first zigzag-shaped element to the common edge of the second zigzag-shaped element at at least one point of intersection.   
     
     
         14 . A multilayer composite comprising:
 at least one cover layer and at least one core layer;   wherein the core layer comprises:
 a plurality of wooden zigzag-shaped elements each comprising zigzagging laminar regions, wherein a zig region of a given element and an adjoining zag region of the given element form between them a common edge; 
 wherein the plurality of zigzag-shaped elements are arranged such that a common edge of a first zigzag-shaped element and a common edge of a second zigzag-shaped element intersect at an angle which is different from zero; and 
 wherein the first zigzag-shaped element and the second zigzag-shaped element are fixedly connected to each other at at least one point of intersection; and 
   wherein the cover layer is arranged such that it least partially covers the core layer and is fixedly connected to the core layer.   
     
     
         15 . A multilayer composite according to  claim 14 , wherein the multilayer composite is compressively deformed. 
     
     
         16 . The multilayer composite according to  claim 14 , wherein the cover layer comprises a material selected from the group of: veneer, woodboard, chipboard, fibreboard, plywood board, plastics sheet, plasterboard, sheet metal, fibre cement board, and combinations thereof.