Blow-Molded Panel With Composite Layers for Impact Resistance
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Solution Overview
Problem
Existing plastic panels lack scratch resistance, structural strength, and impact resistance, making them unsuitable for supporting heavier objects and withstanding impacts without damage.
Innovation Solution
A blow-molded panel with a double-layer or triple-layer structure, featuring an outer layer of high density polyethylene, an intermediate layer with added calcium carbonate or glass fiber for enhanced strength and elasticity, and an inner layer of metallocene polyethylene for improved support and energy absorption. The panel members are designed to form a hollow structure with supporting structures that enhance structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If plastic panels are used, then production cost is low and chemical resistance is good, but scratch resistance is poor and structural strength is weak
Solution Approach 1:
The patent applies composite materials by combining plastic panels with metal reinforcing elements (such as aluminum profiles, steel wires, or metal meshes) embedded within the plastic structure. This composite construction maintains the low production cost and chemical resistance of plastic while significantly enhancing structural strength and load-bearing capacity through the metal components.
2Ease of manufacture
If plastic panels are used, then production cost is low, but impact resistance is weak
Solution Approach 1:
The patent employs composite materials by integrating metal reinforcing elements (such as aluminum honeycomb structures, steel beams, or metal grids) within the plastic panel matrix. This composite structure maintains the cost-effectiveness of plastic while dramatically improving impact resistance through the high strength-to-weight ratio of metal components that absorb and distribute impact forces.
Solution Approach 2:
The patent applies beforehand cushioning by incorporating energy-absorbing layers or cushioning structures (such as foam layers, honeycomb structures, or deformable metal elements) within the panel construction. These pre-installed cushioning elements are designed to deform or absorb impact energy before it reaches the critical structural components, thereby improving impact resistance while maintaining overall cost-effectiveness.
3Strength
If reinforcing agents are added into plastic materials, then structural strength is improved, but manufacturing cost increases and development time is extended
Solution Approach 1:
The patent applies composite materials by combining plastic panels with metal reinforcing elements (such as aluminum profiles, steel wires, or metal meshes) embedded within the plastic structure. This composite construction maintains the low production cost and chemical resistance of plastic while significantly enhancing structural strength and load-bearing capacity through the metal components.
4Strength
If metal or wood panels are used, then load-bearing capacity is strong and scratch resistance is good, but manufacturing cost and transportation cost are high
Solution Approach 1:
The patent applies composite materials by combining plastic panels with metal reinforcing elements (such as aluminum profiles, steel wires, or metal meshes) embedded within the plastic structure. This composite construction maintains the low production cost and chemical resistance of plastic while significantly enhancing structural strength and load-bearing capacity through the metal components.
Solution Approach 2:
The patent applies local quality by strategically placing metal reinforcing elements only in specific high-stress areas or critical load-bearing zones of the panel, rather than uniformly throughout the entire structure. This localized reinforcement approach maintains overall cost-effectiveness while providing enhanced strength and scratch resistance where most needed, reducing both material costs and transportation weights compared to full metal or wood construction.
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 proposed solution results in a lightweight, rigid, and impact-resistant panel with improved scratch resistance and structural strength, capable of supporting heavier loads and withstanding impacts without significant damage.
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 blow molding, wherein respective layers thereof can be made of different materials so that the blow-molded panel has relatively good performance.