Composite Panel Manufacturing via Segmented Core Slabs
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Solution Overview
Problem
Existing methods for manufacturing frame-type composite building panels are limited by the size of the core mold, leading to inconsistencies and restrictions in panel length, as larger molds face challenges in uniformly applying heat for expanding insulating materials.
Innovation Solution
A method involving forming an elongate slab of core material, attaching frame members with slots, and cutting individual panels from the core-frame composite, using rotatable drums with protrusions to create slots for frame members, allowing for panels of varying lengths and configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If the mold length is increased to create larger panels, then the panel length is improved, but the uniformity of heat application deteriorates
Solution Approach 1:
The patent divides the elongate core slab into multiple separately-formed sections that are joined together. Each section can be independently formed in a standard-sized mold with consistent heat application, then connected to create panels of any desired length. This segmentation resolves the contradiction by maintaining uniform manufacturing conditions for each segment while achieving arbitrary overall lengths.
Solution Approach 2:
The patent pre-forms multiple core sections to standardized dimensions before joining them. Each section is manufactured with optimal heat application in a controlled manner, then prepared with attachment features for subsequent joining. This preliminary formation of standardized units ensures consistent quality while enabling flexible final panel lengths.
2Length of moving object
If the mold length is increased to create larger panels, then the panel length is improved, but the consistency of the final product deteriorates
Solution Approach 1:
By segmenting the core into multiple standardized sections, each produced under identical controlled conditions, the patent ensures consistent quality across all segments. The modular nature allows each section to be independently verified for consistency before assembly, maintaining high reliability while achieving any required panel length.
Solution Approach 2:
The patent standardizes the dimensions and properties of each core section as fixed parameters, ensuring that every segment meets the same quality criteria. By controlling the parameters of individual sections rather than attempting to control a single large mold, the system maintains product consistency while allowing variable final panel lengths through selection and combination of standardized segments.
3Ease of manufacture
If standard mold sizes are used, then the manufacturing process is simple, but the panel length is restricted
Solution Approach 1:
The patent uses standard-sized molds to produce segmented core sections, maintaining simple and proven manufacturing processes. These standardized segments are then joined using straightforward connection methods to create panels of any required length. This approach preserves manufacturing simplicity while eliminating length restrictions.
Solution Approach 2:
The standardized core sections serve multiple functions: they can be used individually for short panels, combined in various numbers for medium-length panels, or assembled in sequences for long panels. This universal modular unit enables a single manufacturing process to produce panels across a wide range of lengths, combining simplicity with flexibility.
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
This approach enables the production of composite panels without length restrictions, allowing for custom lengths and different sizes from the same core-frame composite, improving consistency and versatility in panel manufacturing.
Implementation Method 1
a plurality of protrusions depending from the at least one rotatable drum; wherein each of the protrusions cuts a respective one of the slots when the at least one rotatable drum is rotating and the protrusions are contacting and moving across the elongate slab
Implementation Method 2
Dickens forms the insulating core by applying heat to a core-shaped mold containing expandable polystyrene (EPS). The EPS expands under the application of heat to fill the mold
Data Source
AI summary
A method for manufacturing frame-type composite panels to a desired length comprises forming an elongate core-frame composite in which frame members have been received in slots on a slab of core material. The composite is cut to the desired length and the frame is finished by application of end members. The method described herein allows composite frame panels to be formed without restriction on the length typically due to the length of the mold in which the core is formed. A drum for use in a system for creating composite panels is disclosed having protruding rings concentric to the drum. A slab of core material is passed between two such drums which form slots in the slab for receiving frame members when they contact the slabs.