Fiber-Reinforced Composite Board for Lightweight Furniture Shaping

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Solution Overview

Problem

Traditional wooden planks are resource-intensive, difficult to shape, and prone to quality issues due to moisture and temperature, while plastic composite boards lack strength, are heavy, and have complex production processes, limiting their versatility in furniture manufacturing.

Innovation Solution

A composite board composed of a matrix made from varied materials, covered with thermosetting resin and fiber layers, which are melted together to form a strong, lightweight, and easily shaped product with a decorative surface, using methods like foaming and heat pressing without requiring complex devices.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If traditional wooden or matchwood planks are used, then the strength is adequate, but the weight is heavy and the processing is complicated

Engineering Contradiction:

Improveboard strengthVSAvoidboard weight

Core Design Contradiction:

StrengthVSWeight of stationary object

Solution Approach 1:

The patent uses composite materials consisting of wood powder (30-70 parts), thermoplastic resin (10-40 parts), and inorganic filler (10-30 parts) to create a composite board that combines the strength of wood with the lightness and processability of plastics, resolving the contradiction between strength and weight

Inventive Principle:

Principle #40Composite materials

2Strength

If traditional wooden or matchwood planks are used, then the strength is adequate, but the processing procedure is complicated and difficult to be variational shaped

Engineering Contradiction:

Improveboard strengthVSAvoidprocessing complexity

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The thermoplastic resin matrix combined with wood powder and inorganic fillers creates a composite material that can be easily processed using standard plastic processing techniques like extrusion and molding, enabling complex shapes and patterns while maintaining wood-like strength

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent adjusts the ratios of wood powder, thermoplastic resin, and inorganic filler to optimize both strength and processability, demonstrating how parameter changes in composite formulation can resolve manufacturing complexity while maintaining structural integrity

Inventive Principle:

Principle #35Parameter changes

3Weight of stationary object

If plastic composite boards with honeycomb-core plate and foamed plastics are used, then the weight is reduced, but the strength is not strong enough

Engineering Contradiction:

Improveboard weightVSAvoidboard strength

Core Design Contradiction:

Weight of stationary objectVSStrength

Solution Approach 1:

The patent creates a composite material where wood powder provides structural strength, thermoplastic resin provides binding and flexibility, and inorganic filler provides rigidity and dimensional stability, achieving both light weight and high strength simultaneously

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The composite formulation allows different regions of the board to have optimized properties by adjusting the distribution and ratio of components, enabling localized strength enhancement where needed while maintaining overall light weight

Inventive Principle:

Principle #3Local quality

4Weight of stationary object

If plastic composite boards with honeycomb-core plate and foamed plastics are used, then the weight is reduced, but the connection between components is not stable

Engineering Contradiction:

Improveboard weightVSAvoidcomponent connection stability

Core Design Contradiction:

Weight of stationary objectVSStability of the object's composition

Solution Approach 1:

The thermoplastic resin acts as a strong bonding matrix that integrates wood powder and inorganic filler into a unified structure, eliminating the need for separate sticking operations and creating stable, monolithic connections throughout the board

Inventive Principle:

Principle #40Composite materials

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

The solution provides a strong, lightweight, and versatile composite board that can mimic various materials like wood or granite, simplifies production, and allows for easy shaping and decoration, addressing the limitations of traditional and plastic composite boards.

Implementation Method 1

The fiber and thermosetting resin layers would be melted together as a unit in the process of thermosetting

Methodology Applied

Scientific EffectMelting: Melting

Implementation Method 2

using methods like foaming and heat pressing

Methodology Applied

Scientific EffectFoaming: Foam

Implementation Method 3

using methods like foaming and heat pressing

Methodology Applied

Scientific EffectHeat pressing: Heating

Data Source

PatentUS7820087B2Furniture composite board

Publication Date: 2010.10.26 CHEN TE LUNG

AI summary

A furniture composite board comprises different materials. The surface of a proper-shaped matrix is covered by thermosetting resin and then fibers. The fibers then are soaked in thermosetting resin. During the process of thermosetting, the fibers would be solidified and become hard and firm on the surface of the matrix. The composite board has strong strength and its weight would change according to the matrix. It is easy for the composite to form various shapes; easy to be produced and needs no complicated equipment.