Curvilinear Layered Structure Non-Uniform Thickness Manufacturing
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Solution Overview
Problem
Manufacturing curvilinear products with non-uniform thickness is challenging due to the stiffness of thick objects, which makes them difficult to bend without breaking or requiring excessive force.
Innovation Solution
The method involves creating a preform with layers of material attached using thermoplastic material, allowing the layers to slide and bend when heated, reducing flexural stiffness by distributing thickness evenly across multiple layers, and applying a surface layer for aesthetic and protective purposes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a single thick layer is used to achieve non-uniform thickness, then the structural integrity is maintained, but the bendability deteriorates due to excessive stiffness
Solution Approach 1:
The patent divides a single thick layer into multiple thinner layers (e.g., three layers of 2mm each instead of one layer of 6mm). This segmentation reduces the flexural stiffness of each individual layer while maintaining the overall structural integrity through the layered composition, enabling the product to be bent without breaking or requiring excessive force.
2Ease of operation
If multiple layers are used to improve bendability, then the flexural stiffness is reduced, but the manufacturing complexity increases
Solution Approach 1:
The patent combines multiple thinner layers into a single integrated structure where the layers are bonded together. This merging approach allows the layers to act as a unified unit during bending operations, simplifying the manufacturing process compared to handling separate components, while still achieving the desired bendability through the distributed thickness across multiple layers.
3Ease of manufacture
If a uniform thickness is used across the product, then the manufacturing process is simplified, but the visual appeal and surface quality deteriorate
Solution Approach 1:
The patent applies different thicknesses to different regions of the product by controlling the layer distribution. Thinner regions provide visual appeal and surface quality in areas where it is desired, while thicker regions maintain structural integrity and strength where needed. This local variation in thickness is achieved through the layered structure, allowing each region to have optimized properties for its specific function.
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 efficient production of curvilinear products with non-uniform thickness, improving bendability and maintaining structural integrity while achieving a visually appealing and protective finish.
Implementation Method 1
The preform or the intermediate product is heated or has been heated to a second temperature, in which the thermoplastic material is above the melting point
Implementation Method 2
the thermoplastic material transforms to at least partly thermoset material, and the preform or the intermediate product re-gains its rigidity
Data Source
Figure 1a~1c
Figure 2a~2d
Figure 3a~3d
AI summary
A method for producing a curvilinear layered product (300) having a non-uniform thickness. The method comprises, in some order: arranging available a preform (100) having a first thickness at a first location, wherein the preform comprises at least two layers (110) and thermoplastic material (120) in between the two layers; at a first temperature, removing part of the preform or a form pressed preform to form an intermediate product (200) having a second thickness at a second location, wherein the second thickness is smaller than the first thickness; at a second temperature, from pressing the intermediate product or the preform, wherein the second temperature is greater than the first temperature; and arranging at least one surface layer (220) onto one of the preform, the form pressed preform, the intermediate product, and the form pressed intermediate product. A product (300) produced by the method. An intermediate product (200) for producing the product. A device for form pressing the intermediate product.