Galvanized Light Board Stamping with Reflective Layer
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Solution Overview
Problem
The manufacturing of light boards using iron plates is hindered by rust issues, leading to increased costs and production time, while alternatives like galvanized plates complicate the process with deformation and complex layer attachment.
Innovation Solution
A manufacturing method involving a galvanized plate with a polyethylene terephthalate light reflection layer applied to one surface, followed by a stamping process to create a forming space and the placement of light bead bars, enhancing light reflection and illumination performance while providing anti-corrosion protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If iron plate is used for manufacturing light board, then the board structure is simple, but the plate is easy to be rusted and manufacturing cost increases
Solution Approach 1:
The patent uses a composite structure combining galvanized plate (metal substrate with zinc coating for corrosion resistance) and light reflection layer (functional coating). This composite material approach maintains structural simplicity while providing both anti-corrosion performance and light reflection functionality, resolving the contradiction between simple structure and corrosion resistance.
2Reliability
If polypropylene coating layer and polyethylene terephthalate coating layer are applied on iron plate, then the anti-corrosion performance is improved, but the manufacturing cost and manufacturing time increase
Solution Approach 1:
The patent extracts and eliminates the complex multi-layer coating process (polypropylene + polyethylene terephthalate) from the manufacturing workflow. By using galvanized plate which inherently provides corrosion resistance through its zinc coating, the patent removes the need for additional protective coating layers, thereby reducing manufacturing steps, cost, and time while maintaining anti-corrosion performance.
3Reliability
If galvanized plate is stamped first and then light reflection layer is attached, then the anti-corrosion performance is improved, but the manufacturing process becomes complicated due to deformation and cutting requirements
Solution Approach 1:
The patent applies the light reflection layer to the galvanized plate before the stamping process. This preliminary action ensures that the light reflection layer is already in position on the flat plate surface before deformation occurs. During stamping, the layer deforms with the plate but maintains its protective and reflective functions, eliminating the need for post-stamping cutting and attachment operations.
Solution Approach 2:
The patent inverts the conventional manufacturing sequence by applying the light reflection layer before stamping instead of after. This reversal of the process order simplifies manufacturing by avoiding the complexity of cutting and attaching the layer to a pre-deformed plate, while still achieving the desired anti-corrosion and light reflection performance.
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 improves light reflection and illumination efficiency while offering anti-corrosion benefits, simplifying the manufacturing process and reducing costs by using a galvanized plate with a polyethylene terephthalate light reflection layer and forming space for light bead placement.
Implementation Method 1
covering a light reflection layer on one surface of a galvanized plate... increases the light reflection performance of the board
Data Source
AI summary
A manufacturing method for a light board includes step a, covering a light reflection layer on one surface of a galvanized plate; step b, producing a forming space by applying a stamping process along a direction from the light reflection layer to the galvanized plate; and step c, disposing a plurality of light bead bars on the light reflection layer. Accordingly, as one surface of the galvanized plate is covered by the light reflection layer, the application of the light reflection layer at the inner surface of the board increases the light reflection performance of the board so as to improve the whole lighting effect and the illumination performance of the light board. Moreover, as the outer surface of the board is the galvanized plate, the outer surface of the board has the anti-corrosion effect.