Foamed Resin Panel Reinforcing Structure
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Solution Overview
Problem
Conventional resin panels face challenges in reducing weight while maintaining structural integrity, dimensional accuracy, and preventing relative movement of reinforcing materials during the molding process, leading to increased thickness and potential defects in the skin material.
Innovation Solution
A resin panel design featuring a reinforcing material with linear plates and connecting plates, integrated into a foamed structure with accommodating and projecting portions to securely attach the reinforcing material, ensuring stability and accuracy, and preventing movement during molding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the thickness of the resin sheet is increased to support the load of the fastened member, then the fastening strength is improved, but the weight of the resin panel increases
Solution Approach 1:
The invention uses a composite structure combining foam core material with skin material sheets to create a sandwich panel. This composite structure provides high strength-to-weight ratio, allowing the panel to support fastened members without increasing overall thickness or weight. The foam core provides structural support while the skin material sheets provide surface integrity for fastening.
Solution Approach 2:
The resin panel is divided into distinct functional layers: foam core material for structural support and skin material sheets for surface integrity. This segmentation allows each layer to perform its specific function optimally - the foam provides load distribution while the skin material provides a solid base for fastening, avoiding the need to increase overall panel thickness.
2Strength
If the first core material and the second core material are assembled to the reinforcing material from both sides, then the reinforcing effect is improved, but the dimensional accuracy of the foam deteriorates due to assembling errors
Solution Approach 1:
The invention merges the core material and reinforcing material into a single integrated foamed structure with the reinforcing material embedded within the foam. This eliminates the need for separate assembly steps, thereby avoiding dimensional errors that would occur during assembly while maintaining the reinforcing effect.
Solution Approach 2:
The reinforcing material is positioned and fixed within the foam core material before the skin material sheets are attached. This preliminary positioning ensures accurate dimensional alignment is maintained throughout the manufacturing process, preventing assembly errors from affecting the final dimensional accuracy.
3Strength
If the skin material is molded on the surface of the foamed structure including the reinforcing material, then the structural integrity is improved, but the reinforcing material may move relative to the foam during molding, causing defects
Solution Approach 1:
The accommodating portion with the projecting portion is formed in the foam core material before the skin material sheets are molded. The projecting portion preliminarily secures the reinforcing material in position, preventing relative movement during the molding process and ensuring reliable production without defects.
Solution Approach 2:
The projecting portion of the accommodating portion acts as an intermediary element between the reinforcing material and the foam core material. It provides a mechanical interlock that prevents relative movement during molding while allowing the skin material sheets to be properly formed over the reinforcing material, ensuring both structural integrity and molding reliability.
Data Source
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AI summary
A resin panel according to an embodiment includes a core material, a reinforcing material, a skin material covering the core material and the reinforcing material, and a fastened member. A reinforcing material 3 has a first plate provided on a front surface of the core material, a second plate provided on a back surface of the core material, and a connecting plate connecting the first plate and the second plate. The fastened member is attached to the skin material by a fastening member penetrating the skin material and the first plate or the second plate of the reinforcing material.