Composite Suction Plastic Panel With Hidden Vent Marks
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Solution Overview
Problem
Existing plastic table tops made by the suction method have rough and uneven surfaces due to vent marks from the manufacturing process, which are aesthetically unappealing and difficult to manufacture cost-effectively while maintaining strength.
Innovation Solution
A composite suction plastic panel with a top surface featuring concaves that correspond to the positions of the vents in the mould, hiding the vent marks and ensuring a smooth surface, while maintaining a thin and strong structure through a cone-shaped cross-section of the grooves and varying patterns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If vents are disposed in the plastic suction mould to enable the heated softened plastic panel to be sucked to the mould, then the plastic panel can be formed, but the surface of the plastic panel becomes rough and uneven due to vent marks
Solution Approach 1:
The invention converts the harmful vent marks into a beneficial design feature by creating concaves at the vent positions. The concaves are formed by cone-shaped protrusions in the mould that correspond to the vent locations, causing the plastic to sink into these凹 regions during suction forming. This transforms the aesthetic defect into a deliberate decorative pattern while maintaining the necessary vent function for forming.
Solution Approach 2:
The invention applies local quality by creating concaves only at specific positions where vents are located, rather than attempting to eliminate vents entirely or uniformly treating the entire surface. The cone-shaped protrusions are strategically placed in the mould to correspond with vent positions, creating localized concave regions that hide the vent marks while leaving the rest of the surface smooth and attractive.
2Manufacturing precision
If the thickness of the plastic panel is increased to remove vent marks, then the surface quality improves, but the manufacturing cost increases
Solution Approach 1:
Instead of using increased material thickness to cover vent marks, the invention converts the vent marks into decorative concaves. This approach maintains thin panel thickness while achieving smooth surface appearance, thereby reducing material consumption and manufacturing cost while improving surface quality.
Solution Approach 2:
The invention changes the surface topology parameter by creating concaves at vent positions rather than attempting to eliminate the vents or increase thickness. This parameter change allows the panel to maintain its thin profile while achieving the appearance of a smooth surface, thus reducing material usage and cost.
3Quantity of substance
If the plastic panel is made thinner to reduce manufacturing cost, then the cost decreases, but the strength of the panel may be compromised
Solution Approach 1:
The invention creates a composite structure by combining the plastic panel with a bottom plate that has raising portions. These raising portions correspond to the concaves in the panel, creating a sandwich-like composite structure that enhances strength while maintaining thin overall thickness. The composite structure provides the necessary mechanical strength without requiring increased material thickness.
Solution Approach 2:
The invention addresses the strength issue by adding structural complexity in the vertical dimension through the bottom plate with raising portions. This creates a three-dimensional composite structure that provides enhanced strength and stiffness without increasing the planar thickness of the panel, thus maintaining cost-effectiveness while solving the strength problem.
4Productivity
If vents are disposed in the plastic suction mould, then the forming process can be completed, but the aesthetic appearance of the panel deteriorates due to visible vent marks
Solution Approach 1:
The invention converts the aesthetically harmful vent marks into beneficial decorative concaves. By positioning cone-shaped protrusions in the mould at the vent locations, the vent marks become intentional design features that can form patterns or lines on the panel surface, maintaining forming efficiency while dramatically improving aesthetic appearance.
Solution Approach 2:
The invention applies local quality by creating concaves only at the specific vent positions rather than uniformly treating the entire surface. This allows the majority of the panel surface to remain smooth and attractive, while the vent areas are transformed into decorative elements that enhance rather than detract from the overall aesthetic appearance.
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 solution results in a flat and attractive surface, reduced manufacturing costs, and enhanced strength by hiding vent marks and allowing for thinner panels, with the ability to form various patterns for aesthetic appeal.
Implementation Method 1
the heated softened plastic panel is sucked to the mould
Implementation Method 2
following is cooling forming
Data Source
AI summary
The present invention provides a composite suction plastic panel, which comprises a substantially planar and single-layered surface plate and a bottom plate formed by plastic suction mold method, the bottom plate is disposed with a plurality of raisings to support the panel and is adhesively connected to the bottom surface of the surface plate, the top surface of the surface plate is disposed with grooves, the grooves are arranged corresponding to the positions of the vents in the plastic suction mould. The plastic suction mark of the vents is left in the grooves at the time of formation, so that the surface of the plastic surface plate is flat and smooth without a mark of vents.