Composite structural board
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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, which enhances strength and simplifies the manufacturing process by integrating the stiffener with the plastic board, reducing production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a three-layer composite board 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 invention extracts the reinforcement function from a separate reinforcement plate and integrates it into the stiffener component. The stiffener is a single integrated component that combines the reinforcement functions, eliminating the need for a separate reinforcement plate and reducing the number of components from three to two main parts (face plate and stiffener assembly).
Solution Approach 2:
The invention merges the reinforcement plate and reinforcement frame functions into a single stiffener component. The stiffener has a closed frame structure that provides both reinforcement and structural support, combining multiple functions into one element that simplifies the overall assembly.
2Strength
If a three-layer composite board with face plate, reinforcement plate, and reinforcement frame is used, then the strength is improved, but the manufacturing cost increases
Solution Approach 1:
The invention extracts the reinforcement function from a separate reinforcement plate and integrates it into the stiffener component. The stiffener is a single integrated component that combines the reinforcement functions, eliminating the need for a separate reinforcement plate and reducing the number of components from three to two main parts (face plate and stiffener assembly).
Solution Approach 2:
The invention merges the reinforcement plate and reinforcement frame functions into a single stiffener component. The stiffener has a closed frame structure that provides both reinforcement and structural support, combining multiple functions into one element that simplifies the overall assembly.
3Shape
If 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 invention segments the manufacturing process into two independent stages: first forming the plastic face plate through injection molding, then separately forming the metal stiffener and assembling them together. This segmentation allows parallel production of components, significantly reducing the overall production cycle compared to single-stage blow molding of large panels.
Solution Approach 2:
The invention applies preliminary action by pre-forming the stiffener component separately before final assembly. The metal stiffener can be manufactured in advance using efficient metal forming processes, and the plastic face plate can be injection molded independently, allowing both components to be prepared simultaneously rather than sequentially in a single blow molding process.
4Shape
If blow molded plastic board is used for large-scale furniture, then the appearance and cleanability are improved, but the production cost increases
Solution Approach 1:
The invention segments the manufacturing process into two independent stages: first forming the plastic face plate through injection molding, then separately forming the metal stiffener and assembling them together. This segmentation allows parallel production of components, significantly reducing the overall production cycle compared to single-stage blow molding of large panels.
Solution Approach 2:
The invention applies preliminary action by pre-forming the stiffener component separately before final assembly. The metal stiffener can be manufactured in advance using efficient metal forming processes, and the plastic face plate can be injection molded independently, allowing both components to be prepared simultaneously rather than sequentially in a single blow molding process.
5Ease of manufacture
If injection molded plastic board is used, then the production cost is reduced, but the strength is limited
Solution Approach 1:
The invention creates a composite structure combining plastic (face plate) and metal (stiffener) materials. The injection-molded plastic face plate provides cost-effectiveness and aesthetic qualities, while the integrated metal stiffener provides enhanced structural strength and rigidity, achieving a synergistic effect that overcomes the limitations of either material alone.
Data Source
Figure 1~4
Figure 5~6
Figure 7A~7B
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.