Door Panel Magnetic Jig Positioning for Flat Surface Filling
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Solution Overview
Problem
Existing door panel manufacturing processes face issues with deformation and damage due to uneven pressure from expanding filling materials, and the use of jigs results in residual glue and increased labor for removal, affecting surface beauty and efficiency.
Innovation Solution
The method involves pre-processing panels with recessed and protruding portions, using magnetically attracted materials on protruding portions, and embedding magnets in jigs for magnetic attraction to secure panels during filling, eliminating the need for tape or adhesive methods and preventing deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If tape or adhesive tape is used to position panels on jigs, then panels are firmly fixed for processing, but residual glue adheres to panel surfaces after jig separation, requiring additional labor and time for removal
Solution Approach 1:
The patent replaces the chemical bonding mechanism (adhesive tape) with a magnetic field-based retention system. Magnets embedded in the jigs create magnetic attraction forces that hold panels during processing, allowing for easy separation without residual adhesive. This substitution eliminates the need for glue removal operations while maintaining secure positioning during the filling process.
2Stability of the object's composition
If adhesive methods are used to secure panels, then panels remain fixed during filling, but surface beauty and flatness are compromised due to residual glue
Solution Approach 1:
The patent substitutes adhesive bonding with magnetic attraction to secure panels during the filling process. The magnets embedded in the jigs create sufficient holding force to prevent panel movement while avoiding contact with the panel surface, thereby maintaining surface flatness and aesthetic quality without requiring post-processing removal operations.
3Strength
If conventional jig methods with adhesive are used, then panels are securely positioned, but additional human resources and costs are required for glue removal
Solution Approach 1:
The patent replaces adhesive-based positioning with a magnetic field system where magnets embedded in the jigs provide secure panel retention during processing. The magnetic attraction allows for easy separation without residual adhesive, eliminating the need for additional labor and resources dedicated to glue removal, thereby improving overall manufacturing efficiency.
4Quantity of substance
If filling material is filled into the main body, then sound and heat insulation are achieved, but filling material expands and causes deformation or cracks in decorative design parts
Solution Approach 1:
The patent applies preliminary action by positioning support jigs with embedded magnets onto the panel surfaces before filling the main body with expanding filling material. These jigs provide counteracting support forces that prevent deformation and cracking of decorative design parts during the expansion process, ensuring shape accuracy is maintained throughout filling operation.
Solution Approach 2:
The patent implements preliminary anti-action by using support jigs positioned on the panel surfaces to counteract the outward expansion forces of the filling material. The jigs apply opposing forces that prevent deformation and cracking of the decorative design parts, effectively neutralizing the harmful effects of material expansion before they can cause damage.
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 ensures panels are firmly held, maintaining surface beauty and flatness, reduces labor and time, and prevents deformation, thus improving yield and reducing costs.
Implementation Method 1
a magnet embedded inside each jig performs magnetic attraction on the magnetically attracted material on the surface of each protruding portion
Data Source
AI summary
A door panel manufacturing method is provided. There is a filling space inside the frame of the door panel for the filling of a filling material to be, and the two panels of the door panel are respectively combined with the hollows on both sides of the frame to seal the filling space. Each panel has one side processed to provide a recessed portion so that a protruding portion corresponding to the recessed portion is formed on the other side and combined with a magnetically attracted material. In the manufacturing operation, jigs respectively provided with a magnet are assembled on the recessed portions to magnetically attract the panels for positioning, thereby preventing the residual glue formed when the jigs are detached from the surfaces of panels, and effectively maintaining the beauty and flatness of the surfaces of the panels.