Fiber Composite Room Divider Molding With Integrated Cavity Bonding
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Solution Overview
Problem
The challenge is to produce room dividers with a flexible surface design efficiently, as existing methods are complex and lack simplicity in production processes.
Innovation Solution
A method involving heating two fiber composite mats to a forming temperature, pressing them together in a mold to create a flat molded part with a cavity, and fastening a mounting element, using plastic components with a melting temperature below the forming temperature to bond the mats and form a one-piece flexible textile fabric.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple production steps are used to create room dividers with flexible surface design, then manufacturing precision and design flexibility are improved, but device complexity and production time increase
Solution Approach 1:
The patent combines heating, pressing, forming, and cavity creation into a single integrated molding process. The mold applies heat and pressure simultaneously to form the room divider with curved surfaces and embedded mounting element cavities in one operation, eliminating the need for separate production steps while achieving complex flexible designs
Solution Approach 2:
The molding process serves multiple functions simultaneously: it heats the fiber composite material, applies pressure for consolidation, forms curved surfaces, creates cavities for mounting elements, and produces the final shaped room divider all in one operation, making the process highly versatile and efficient
2Manufacturing precision
If multiple production steps are used to form curves and edges, then manufacturing precision is improved, but productivity decreases
Solution Approach 1:
The patent combines curve formation, edge definition, and cavity creation into a single molding operation. The mold geometry directly imparts the desired curved surfaces and edges while simultaneously forming cavities for mounting elements, achieving high precision without requiring multiple sequential steps that would reduce productivity
3Strength
If fiber composite mats are bonded using traditional methods, then bond strength is improved, but production complexity and time increase
Solution Approach 1:
The patent utilizes the phase transition of the plastic component from solid to molten state during heating. The plastic melts and flows between fibers, creating strong bonds as it solidifies upon cooling. This phase change enables effective bonding of fiber composite mats through the molding process itself, eliminating the need for separate bonding operations and reducing production complexity
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 allows for the simple production of flexible room dividers with curved designs in a single production step, achieving high throughput and enabling easy formation of curves and edges, while also being recyclable and adaptable for various applications.
Implementation Method 1
heating two fiber composite mats 2 to a forming temperature... One-piece fiber mats with a plastic component that is brought into a deformable and/or flowable state by means of heat treatment... the melted plastic material is distributed between the fibers and thereby bonds them together
Data Source
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AI summary
The present invention relates to a method for manufacturing a room divider (1) from fiber composite mats (2), comprising heating two fiber composite mats (2) to a forming temperature, pressing the two heated fiber composite mats (2) together in a single working stroke of a forming tool (4) to form a planar molded part corresponding to a shape of the room divider (1), wherein a cavity (8) is formed between the two fiber composite mats (2) by inserting a mold core (7) between the two fiber composite mats (2) and withdrawing it after pressing, and attaching a mounting element (9) in the cavity (8) for mounting the room divider (1), wherein the fiber composite mats (2) are each formed as a one-piece flexible textile sheet with a plastic component which has a melting temperature below the forming temperature.