Honeycomb Panel Foam Inserts for Fastener Anchoring
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Solution Overview
Problem
The manufacturing of honeycomb composite panels for furniture is hindered by the complexity and cost of attaching fastening means like dowels and hinges, requiring cumbersome and expensive processes due to the need for additional frames and intricate fastening systems.
Innovation Solution
A method involving the introduction of plastic foam inserts into specific areas of the honeycomb core during production, where fasteners will be anchored, eliminating the need for additional frames and simplifying the manufacturing process by allowing for automatic production and reduced material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If conventional honeycomb panels with thin wood-based panels and honeycomb paper core are used, then weight is reduced, but the attachment of fastening means becomes complex and expensive
Solution Approach 1:
The patent applies preliminary action by introducing plastic foam composition into the honeycomb core cells during the manufacturing process, before the panel is put into service. This pre-formation of foam inserts creates ready-to-use anchoring points that eliminate the need for complex fastening systems later. The foam is introduced through marked areas of the honeycomb core, allowing subsequent easy insertion of fastening means without requiring additional frames or intricate attachment mechanisms.
2Weight of moving object
If supporting edges are used instead of solid frames, then weight is saved, but the process of inserting fasteners by hand becomes cumbersome and expensive
Solution Approach 1:
The patent implements self-service by enabling automatic production of honeycomb panels with pre-formed foam inserts that are ready to receive fastening means. The marked areas on the honeycomb core guide the automatic introduction of plastic foam composition, and the resulting foam inserts automatically create the necessary anchoring structures. This eliminates the need for manual insertion processes and allows the production line to operate automatically, significantly improving productivity.
3Strength
If plastic foam is used to reinforce honeycomb panels, then mechanical strength and insulation capacity increase, but the attachment of fastening means remains problematic
Solution Approach 1:
The patent applies local quality by introducing plastic foam composition exclusively into specific marked areas of the honeycomb core, rather than filling the entire core. This creates localized foam inserts at precise positions where fastening means need to be attached. The marked areas guide the selective foam introduction, ensuring that foam is present only where needed for fastener anchoring, while maintaining the lightweight and insulating properties of the honeycomb structure in non-marked areas.
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 simplifies the fastening technology, reduces material and weight consumption, and enables the production of honeycomb panels with improved mechanical strength and cost-effective fastening systems, facilitating the production of furniture with enhanced properties.
Implementation Method 1
introducing a composition forming a plastic foam exclusively in at least one spatially limited and marked area of the honeycomb core
Implementation Method 2
a composition forming a plastic foam is introduced only into the areas of the honeycomb core that are used for later anchoring of fastening means
Data Source
Figure 1
Figure 2~5
AI summary
Manufacture of composite honeycomb panel with plastic foam involves providing wood material board (a1), applying adhesive layer (a2) on wood material board (a1), placing honeycomb core(s) on adhesive-containing layer which is provided with wood particle board (a1) and bonding honeycomb core to the wood material board (a1), introducing plastic foam composition to the honeycomb core, applying adhesive-containing layer (b2) on the free surface of the honeycomb core, placing plate (b3) on the timber is provided with the adhesive layer (b2), and curing panel. An independent claim is included for composite honeycomb panel.