Composite Structural Board With Integrated Stiffener and Protrusion Support
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Solution Overview
Problem
Current composite structural boards used in furniture manufacturing, such as those with a three-layer structure involving a face plate, reinforcement plate, and reinforcement frame, are complex and costly to produce, with limited strength and long production cycles, especially for large-scale furniture products.
Innovation Solution
A composite structural board design featuring a face plate with a main body and peripheral portion, a base plate with uniformly distributed protrusions, and a stiffener with a closed frame cross-section, where the stiffener is fixedly connected to both the base plate and the face plate, enhancing the strength and simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a three-layer composite structure with face plate, reinforcement plate, and reinforcement frame is used, then the strength is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines the reinforcement plate and reinforcement frame into a single integrated reinforcement structure. The reinforcement structure includes a frame portion and a plate portion that are formed as one piece, eliminating the need for separate components and complex assembly processes while maintaining the strength benefits of both elements
Solution Approach 2:
The reinforcement structure is segmented into functional portions (frame portion and plate portion) with different geometries and positions, allowing each portion to serve its specific structural function while being manufactured as a single integrated component
2Shape
If a blow molded plastic board is used for large-scale furniture, then the appearance and cleanability are improved, but the production cycle increases and manufacturing efficiency decreases
Solution Approach 1:
The face plate and base plate are merged into a single injection-molded piece, eliminating the need for separate molding and assembly processes. This integrated manufacturing approach maintains the aesthetic appearance of blow-molded plastic while dramatically reducing production time and improving manufacturing efficiency
3Productivity
If injection molding is used for plastic board, then the production cycle is reduced, but the strength is limited
Solution Approach 1:
The patent creates a composite structure by integrating a reinforcement structure (made of rigid material such as metal or rigid plastic) into the injection-molded plastic board. This composite design combines the rapid production capabilities of injection molding with the high strength properties of the reinforcement material, achieving both short production cycles and high strength
Solution Approach 2:
The structure is divided into the plastic board portion (face plate and base plate) and the reinforcement portion, allowing each to be optimized for its specific function while being manufactured efficiently as an integrated unit
Data Source
AI summary
A composite structural board is disclosed, which comprises a face plate (2), the face plate (2) having a main body portion (2c) that is substantially in one plane and a peripheral portion (2a) surround the main body portion formed by bending the main body portion downwards, the face plate (2) having an upper surface and a lower surface; the board further comprising a base plate (3) provided with a plurality of substantially uniformly distributed and integrally formed protrusions, the lower surface of the face plate (2) being attached to and supported on top faces of the protrusions; and the board further comprising a stiffener (4) for fixedly connecting the peripheral portion (2a) of the face plate (2) and the base plate (3) together, wherein at least a part of the stiffener (4) is fixedly connected to the base plate (3), and at least another part of the stiffener (4) is fixedly connected to at least a part of a lower surface of the peripheral portion (2a) of the face plate. With the above-described structure, the strength of the composite structural board can be further increased while the number of components is reduced, and the production costs are greatly lowered.