Curved Laminated Panel Shaping Using Distributed Load
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Solution Overview
Problem
Existing methods for creating curved laminated panels require pre-curving of metal sheets and bonding with insulating layers, leading to complex manufacturing processes and high costs.
Innovation Solution
A method involving a distributed load applied to a flat laminated panel to create curvature, utilizing a first layer with local depressions, where stress is absorbed by a filler layer and transmitted to outer layers, allowing for gradual shaping into desired curvatures without pre-curving.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If pre-curving of metal sheets is performed before bonding with insulating layers, then the desired curved shape is achieved, but the manufacturing process becomes complex and production costs increase
Solution Approach 1:
The patent applies preliminary corrugation to the metal sheets before assembly, creating pre-formed ridges and valleys that enable subsequent curved shaping. This preliminary structural preparation allows the panels to be bent into curved configurations without requiring complex pre-curving equipment or multi-step forming processes, thereby achieving the desired curved shape while maintaining manufacturing simplicity
Solution Approach 2:
The patent creates a composite structure by bonding corrugated metal sheets with insulating materials (such as foam or fibrous insulation) to form integrated curved panels. The combination of the rigid corrugated metal framework and the compliant insulating material allows the composite panel to achieve and maintain curved shapes while simplifying the overall manufacturing process, as the insulating layer conforms to the metal sheet curvature during assembly
2Shape
If pre-curving of metal sheets is performed before bonding with insulating layers, then the desired curved shape is achieved, but production costs increase
Solution Approach 1:
The corrugation is pre-formed on standard metal sheets using conventional rolling or pressing techniques before assembly, allowing the sheets to be stocked and transported in their corrugated state. This preliminary action eliminates the need for expensive on-site curving equipment and complex multi-step forming operations, thereby reducing production costs while maintaining the ability to create various curved configurations during installation
Solution Approach 2:
The corrugated metal sheets serve multiple functions: they provide structural strength, enable curved shaping, and create channels for insulation placement. This multi-functionality reduces the need for additional specialized components or processes, simplifying manufacturing and reducing overall production costs while achieving the desired curved shape
3Productivity
If standard flat laminated panels are used to achieve curvature, then costs are reduced and productivity increases, but a method for applying distributed load must be implemented
Solution Approach 1:
The curving process is segmented into discrete localized depressions rather than requiring continuous complex forming. The distributed load is applied in segments across the panel surface, creating a series of controlled local deformations that collectively form the desired curved shape. This segmentation simplifies the curving mechanism, allowing it to be implemented with simpler loading devices while maintaining high productivity
Solution Approach 2:
The patent uses an intermediary distributed load mechanism that transfers force from the curving device through the insulating layer to the metal sheets. This intermediary load distribution system allows standard flat panels to be curved without requiring complex direct contact forming tools, as the load is distributed through the panel assembly itself, simplifying the curving mechanism while achieving the desired result
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
Enhances productivity and reduces costs by enabling the use of standard flat panels to achieve any desired curvature, with minimal additional costs.
Implementation Method 1
A force, applied as a distributed load, acts on the first layer, causing a local depression in the first layer. This force is absorbed by the tension in the third layer's material, which transmits the stress to the first layer and passes it through the third layer to the second layer.
Implementation Method 2
Through the adhesive forces between the third and second layers, the second layer also becomes curved.
Data Source
AI summary
The disclosure refers to the creation of a curved laminated panel from a flat laminated panel or a panel with another type of curvature. The flat or differently curved laminated panel has two outer layers in the form of malleable sheets and an inner layer. Forces are applied to the panel in the form of a distributed load, which determines the desired curvature and radius of the curved layered product, representing the final product.