Honeycomb WPC Decking Profile for Weight Reduction
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Solution Overview
Problem
Existing honeycomb bodies and wood plastic composites (WPC) used in decking and other applications are heavy due to high density, making them difficult to handle and expensive to produce, while lacking anisotropic properties that enhance strength.
Innovation Solution
Honeycomb bodies with hollow longitudinal structures perpendicular to the load direction, made from plastic and natural material composites, featuring thin-walled channels and optimized cross-sectional shapes, significantly increase strength and reduce density, allowing for material savings and easier handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If solid WPC or high-density materials are used for decking and consumer goods, then strength and durability are improved, but weight increases significantly making handling difficult
Solution Approach 1:
The solid material is segmented into a honeycomb structure with multiple hollow longitudinal channels separated by thin wall sections. This segmentation maintains structural integrity while dramatically reducing weight - the patent reports up to 80% weight reduction compared to solid WPC, while preserving flexural strength through the distributed hollow structure.
Solution Approach 2:
The invention employs a porous honeycomb structure with hollow longitudinal channels throughout the material. This porous configuration reduces density and weight while the geometric arrangement of cells provides structural support. The patent specifies that hollow structures with diameters of 5-50mm separated by 2-10mm wall sections achieve optimal balance between weight reduction and strength retention.
2Ease of manufacture
If traditional extrusion methods are used for producing decking, then production is simple, but the resulting products are very heavy and expensive to handle
Solution Approach 1:
The extrusion process incorporates a multi-cavity mold that forms hollow longitudinal channels within the decking profile during a single continuous operation. This segmentation is achieved by positioning multiple mandrels or pins within the extrusion die, creating the honeycomb structure as the material is extruded. The process maintains manufacturing simplicity while producing lightweight structures.
Solution Approach 2:
The invention modifies the extrusion parameters by controlling the geometry of hollow channels (diameter 5-50mm, wall sections 2-10mm) and the distribution pattern of cells. These parameter changes transform the solid extruded profile into a lightweight honeycomb structure that retains strength while reducing weight by up to 80% compared to solid WPC decking.
3Object-affected harmful factors
If WPC is used to conserve natural wood resources, then environmental sustainability is improved, but the high density makes panels very heavy and difficult to handle
Solution Approach 1:
The solid WPC panels are transformed into honeycomb structures with hollow longitudinal channels, segmenting the material volume while maintaining surface integrity. This segmentation reduces weight by up to 80%, making panels significantly easier to handle, transport, and install, while the recycled WPC material continues to provide environmental sustainability benefits by conserving natural wood resources.
Solution Approach 2:
The invention utilizes WPC (wood-plastic composite) material in a honeycomb configuration, combining the environmental benefits of recycled plastics and wood fibers with the structural advantages of cellular geometry. The composite material maintains its sustainability credentials while the honeycomb structure dramatically improves handling characteristics by reducing density and weight.
Data Source
AI summary
The invention relates to a honeycomb body (1), consisting at least of a base body, wherein the at least one base body includes a plurality of hollow longitudinal structures (2) that are axially parallel to one another, wherein the honeycomb body is formed from an extruded plastic material and/or a composite material consisting of a natural material and a plastics material.