Door Leaf Foaming Adhesive Wedge Cavity
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Solution Overview
Problem
Current methods for producing door leaves with non-plane-parallel filling surfaces are time-consuming and material-intensive, requiring extensive milling and multiple sanding and priming steps to achieve a smooth, aesthetically pleasing design.
Innovation Solution
The method involves using a foaming adhesive system to create a wedge-shaped cavity in the door body, allowing for precise placement of cover plates with non-plane-parallel surfaces, eliminating the need for extensive milling and additional coating by gluing a ready-coated panel or cutting and gluing upper cover plates with minimal effort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If extensive milling is used to create non-plane-parallel filling surfaces, then the desired surface design is achieved, but production time and material consumption increase significantly
Solution Approach 1:
The top layer is pre-coated with the final surface design before the filling area is milled out. By preparing the surface coating in advance and protecting it during the milling process, the patent eliminates the need for subsequent sanding and priming steps that would otherwise be required to restore the surface after milling.
Solution Approach 2:
The door leaf is divided into distinct layers (top layer with top coat, middle layer, rear layer) that can be processed independently. The top layer is separated from the filling area during milling, allowing the surface coating to be preserved while the filling is created, avoiding the need to reprocess the entire surface.
2Manufacturing precision
If multiple sanding and priming steps are applied to achieve a smooth surface after milling, then surface quality is improved, but production complexity and material consumption increase
Solution Approach 1:
The top coat is applied to the top layer before the filling area is milled out. This preliminary coating action ensures that the final surface quality is achieved in advance, eliminating the need for subsequent sanding and priming operations that would add complexity to the production process.
Solution Approach 2:
The top layer with its pre-applied top coat serves its own surface preparation function. By preserving the top coat during the filling creation process, the top layer automatically provides the required smooth, high-quality surface without requiring additional external processing steps.
3Shape
If the top layer is removed and reapplied after milling, then the filling area can be created, but the production process becomes more complex and time-consuming
Solution Approach 1:
The top layer is prepared with the top coat applied in advance, before the filling area is milled out. This preliminary preparation allows the filling to be created by simply removing portions of the top layer rather than removing and reapplied entire layers, significantly simplifying the process and improving productivity.
Solution Approach 2:
Instead of removing the entire top layer and reapplying it, the patent extracts only the necessary portions of the top layer to create the filling area. This selective removal approach maintains production efficiency while achieving the desired filling shape.
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 simplifies the production process, reduces material consumption, and eliminates the need for multiple sanding and priming steps, resulting in a high-quality door leaf with a unique surface design while maintaining the integrity of the top layer.
Implementation Method 1
a foaming adhesive system is preferably used here
Data Source
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AI summary
The process is used to manufacture a door leaf that has at least one infill area. The infill area has a surface that is not parallel to at least one cover plate. At least one cover plate has a recess for the infill area. The infill is fixed within the infill area.