Decorative Panel Opening Formation via Two-Stage Punching
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Solution Overview
Problem
Existing methods for forming decorative panels, such as those made of glass fiber reinforced polypropylene, often result in over-stretching and unpleasant stress edges due to breather holes formed during punching, which can be addressed by using a punching die with specific die protrusions and cavities to create openings with reduced stress edges.
Innovation Solution
A method involving a punching die with first and second die halves, where the first die half presses to form a protrusion and the second die half cuts the protrusion using a laser to remove the tip portion, forming openings with controlled angles and depths to minimize stress edges, and a second force is applied to bend the remaining wall away from the opening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If breather holes are formed by directly punching on the decorative panel during molding, then the panel can be efficiently produced, but stress edges and over-stretching occur
Solution Approach 1:
The punching process is segmented into two distinct stages: first forming a protrusion, then cutting the tip portion. This segmentation allows each stage to be optimized independently, preventing the direct punching that causes stress edges while maintaining production efficiency.
Solution Approach 2:
The protrusion is formed as a preliminary action before the actual cutting of the opening. This preliminary protrusion formation allows the material to be pre-positioned and pre-deformed in a controlled manner, preventing over-stretching during the final cutting stage.
2Object-affected harmful factors
If periphery seal is used around the panel to reduce stress edges, then stress edges are partially mitigated, but the solution does not entirely eliminate them and adds complexity
Solution Approach 1:
The harmful tip portion causing stress edges is extracted and removed from the panel through the two-stage punching process. Instead of trying to mitigate stress edges with additional seals, the problematic portion is completely taken out, eliminating the harm at its source.
3Object-affected harmful factors
If hole concealment is used to cover breather holes, then stress edges are concealed, but the functional openings are hidden and aesthetic appeal is reduced
Solution Approach 1:
The two-stage punching process creates different local qualities: the main opening provides functionality while the removed tip portion eliminates stress edges. The resulting clean edges around the opening provide aesthetic appeal without needing concealment, as the edges themselves are of high quality.
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 method effectively reduces stress edges and enhances visual appeal while maintaining cost efficiency, allowing for the formation of decorative panels with visually appealing edges without the drawbacks of existing methods.
Implementation Method 1
The cutting may be carried out by applying laser to remove the tip portion
Data Source
AI summary
The present invention in one or more embodiments provides a method of forming an opening on a panel, the method including pressing in a first direction on the panel to form a protrusion with a tip portion, and cutting the protrusion with a force in a second direction to remove the tip portion to form the opening on the panel, the second direction being different from the first direction. The first direction may be a direction of gravity plus and minus up to 15 degrees. The second direction may be transverse to the first direction with an angle differential there-between of 75 to 105 degrees.