Folded Panel Manufacturing with Template-Guided Transition Section
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Solution Overview
Problem
Existing methods for manufacturing folded panels often result in unpredictable transition sections during bending, leading to potential breakage and inconsistent shapes, which can be a challenge for applications requiring precise curvature and stability.
Innovation Solution
A template with a curved end face is inserted into the recess before folding, guiding the transition section to a predefined shape, and then removed after folding, ensuring consistent angles and minimizing adhesive usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If adhesive is applied as filler in the recess to support the transition section, then the folded condition is stabilized, but the transition section shape becomes unpredictable and breakage risk increases
Solution Approach 1:
A template is inserted into the recess before the folding operation to pre-establish the correct geometric path for the transition section. This preliminary action ensures that when folding occurs, the transition section follows a predetermined trajectory, guaranteeing consistent shape and position regardless of adhesive properties.
Solution Approach 2:
The template acts as an intermediary element between the folding mechanism and the transition section. It provides a physical guide that mediates the bending process, ensuring the transition section achieves the desired curvature and position without direct reliance on adhesive support during the critical shaping phase.
2Manufacturing precision
If template is inserted into recess before folding to guide transition section, then shape consistency is improved, but manufacturing complexity increases
Solution Approach 1:
The manufacturing process is segmented into distinct sequential steps: template insertion, folding operation, template removal, and adhesive application. This segmentation allows each step to be optimized independently and simplifies the overall process control, as the template is a simple geometric element rather than a complex mechanism.
Solution Approach 2:
The template is designed as a simple, inexpensive, single-use component that is inserted and then removed after serving its guiding function. Its temporary nature means it doesn't need to be durable or complex, just sufficiently rigid to guide the folding. This approach keeps the added complexity minimal while achieving the precision goal.
3Reliability
If template is used to define precise folding path, then transition section breakage is minimized, but adhesive usage increases
Solution Approach 1:
The template pre-establishes the correct geometry and position of the transition section before adhesive is applied. This preliminary shaping ensures that the transition section is already in its final desired configuration, minimizing the need for excessive adhesive to maintain position and reducing overall adhesive consumption.
Solution Approach 2:
The template enables the transition section to self-position and self-shape during the folding process through geometric constraint alone, without relying on adhesive forces. This self-service mechanism during the critical folding phase reduces the burden on the adhesive, allowing for more efficient adhesive usage.
Data Source
Figure 1~3
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Figure 6
AI summary
Method for manufacturing a folded panel (1') including the following steps: providing a longitudinal recess (6) at the rear side (3), such that at the front side (2) between remaining panel sections (1a, 1b) on both sides of the recess (6) a flexible transition section (7) remains, bending the panel sections (1a, 1b) relative to each other and applying an adhesive in the recess (6). Before the panel sections (1a, 1b) are bent relative to each other, a template (8) is inserted into the recess.