Method of manufacturing a panel, a panel and furniture comprising a panel
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Solution Overview
Problem
Existing furniture panels manufactured by vacuum forming lack strength and are prone to deformation due to the need for demolding, which does not meet user demands for stability and longevity.
Innovation Solution
A method of manufacturing panels by wrapping a frame within a plastic panel using a vacuum forming process, where the frame is embedded within the plastic sheet, ensuring the panel retains strength and stability while maintaining a smooth profile.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If vacuum forming process is used to manufacture panels, then smooth profile is achieved, but panel strength is insufficient and deformation occurs
Solution Approach 1:
The patent creates a composite structure by embedding a frame within the plastic panel during vacuum forming. The frame (made of rigid material) provides structural strength and anti-deformation capability, while the plastic panel maintains its smooth profile. This composite construction resolves the contradiction between achieving a smooth surface and ensuring panel strength.
2Strength
If frame is embedded within plastic panel during vacuum forming, then panel strength increases, but process complexity increases
Solution Approach 1:
The patent merges the frame placement and panel forming operations into a single integrated vacuum forming process. The frame is positioned on the mold before the plastic sheet is formed, and both are shaped simultaneously in one vacuum forming cycle. This integration avoids the need for separate assembly steps, thereby reducing overall process complexity despite adding the frame embedding feature.
3Shape
If frame protrusion is trimmed after vacuum forming, then smooth surface is maintained, but manufacturing time increases
Solution Approach 1:
The patent incorporates the frame protrusion design into the initial vacuum forming process. The frame is positioned with intentional protrusions that extend beyond the mold surface during forming. These protrusions are then trimmed to the final dimensions in a single operation immediately after forming, rather than requiring multiple iterative adjustments. This preliminary positioning and single-trim approach reduces total manufacturing time while maintaining surface smoothness.
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 method results in panels that are invulnerable to deformation and have a prolonged service life, offering both high strength and a smooth profile.
Implementation Method 1
applying a suction force in a direction perpendicular to the extension direction of the panel to shape the plastic blank sheet by vacuum forming process
Data Source
AI summary
A method of manufacturing a furniture panel includes placing the frame on a top of a mold, the frame at an outer edge being formed with a protrusion; shaping the plastic blank sheet by vacuum forming such that the plastic blank sheet wraps the frame and the mold; demolding and trimming, so that the trimmed plastic blank sheet wraps the protrusion of the frame and the frame is embedded in the trimmed plastic blank sheet. The method is efficient, implementing the process of wrapping a frame within a plastic panel in a simple fashion, and the panel formed smooth in profile. The panel is resistant to deformation and has a prolonged service life.