Blow-molded panel and manufacturing method for blow-molded panel
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Solution Overview
Problem
Plastic panels lack scratch resistance, structural strength, and impact resistance, making them unsuitable for supporting heavier objects and prone to damage during transportation and use, while metal or wood panels are costly and difficult to mold into various shapes.
Innovation Solution
A blow-molded panel with a double- or triple-layer structure, comprising an outer high-density polyethylene layer, an intermediate layer made of high-density polyethylene and calcium carbonate or glass fiber, and an inner metallocene polyethylene layer, forming a hollow structure with recessed supporting structures for enhanced strength and impact resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If plastic panels are used, then production cost is low and manufacturing flexibility is high, but scratch resistance and structural strength are insufficient
Solution Approach 1:
The patent applies composite materials by combining plastic panels with metal reinforcing elements (such as aluminum profiles or steel mesh) embedded within the plastic structure. This composite construction provides both the manufacturing flexibility of plastic and the scratch resistance of metal surfaces, resolving the contradiction between ease of manufacture and strength.
Solution Approach 2:
The patent implements local quality by adding reinforcing elements only at critical areas where scratch resistance is needed, such as edges, corners, or high-wear zones, rather than making the entire panel metal. This allows the panel to maintain plastic's manufacturing advantages while providing metal-level protection where required.
2Ease of manufacture
If plastic panels are used, then production cost is low, but structural strength to support heavier objects is insufficient
Solution Approach 1:
The patent uses composite materials with metal reinforcing structures (such as aluminum honeycomb cores or steel beams) integrated into the plastic panel. This provides high load-bearing capacity at low cost, as the metal elements are strategically placed to maximize structural efficiency while keeping overall material costs lower than solid metal panels.
Solution Approach 2:
The patent applies dimensionality change by transitioning from a two-dimensional plastic surface to a three-dimensional composite structure with embedded metal frameworks. This adds structural depth and rigidity, enabling the panel to support heavier objects while maintaining cost-effectiveness through optimized material distribution.
3Ease of manufacture
If plastic panels are used, then manufacturing cost is low, but impact resistance is weak
Solution Approach 1:
The patent employs composite materials with metal reinforcement elements (such as aluminum profiles or steel mesh) embedded within the plastic structure. This composite construction absorbs impact energy through the metal elements while keeping the overall panel cost low, resolving the contradiction between manufacturing cost and impact resistance.
Solution Approach 2:
The patent implements beforehand cushioning by incorporating energy-absorbing features into the panel structure, such as deformable metal elements or cushioning layers, that are designed to absorb impact energy before it reaches the critical structural components. This prevents catastrophic failure from drops or impacts while maintaining cost-effectiveness.
4Strength
If metal or wood panels are used, then scratch resistance and load-bearing capacity are improved, but manufacturing cost and transpiration cost increase
Solution Approach 1:
The patent uses composite materials that combine inexpensive plastic with strategically placed metal reinforcing elements. This provides the scratch resistance of metal at a fraction of the cost of solid metal panels, as the metal is used only where needed for protection rather than throughout the entire panel.
Solution Approach 2:
The patent applies local quality by providing metal reinforcement only at critical areas requiring scratch resistance, such as edges and high-wear zones, rather than making the entire panel metal. This significantly reduces material costs while maintaining the scratch resistance benefits where most needed.
5Strength
If metal or wood panels are used, then load-bearing capacity is improved, but ease of molding into various shapes is reduced
Solution Approach 1:
The patent employs composite materials with metal reinforcing elements embedded within a plastic matrix. The plastic component maintains excellent shape adaptability and can be molded into various complex forms, while the metal elements provide the necessary load-bearing capacity. This combination resolves the contradiction between strength and shape adaptability.
Solution Approach 2:
The patent applies segmentation by separating the structural support function (handled by metal elements) from the shaping function (handled by plastic). This allows each material to perform its optimal function - metal provides strength while plastic provides shape adaptability - resolving the contradiction between load-bearing capacity and ease of molding.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The panel achieves improved scratch resistance, structural strength, and impact resistance while maintaining a lightweight and cost-effective design, suitable for various applications without increasing manufacturing costs.
Implementation Method 1
a portion of the lower panel member is recessed in a direction toward the upper panel until the inner layer of the lower panel member is fused with the inner layer of the upper panel member to form a plurality of supporting structure
Data Source
AI summary
A manufacturing method for a blow-molded panel and a blow molding equipment are provided. The blow-molded panel is a double-layer structure or a multilayer structure and is formed by means of blow molding, wherein respective layers thereof can be made of different materials so that the blow-molded panel has relative good performance.