Injection-Molded Wickerwork Panel for Outdoor Furniture Durability

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Solution Overview

Problem

Natural wicker materials are unsuitable for outdoor use due to poor resistance to water and heat, and their scarcity leads to increased costs, while existing artificial wicker solutions lack the durability and aesthetic appeal of natural wicker.

Innovation Solution

A panel manufactured through injection molding that mimics natural wickerwork, featuring interlaced warp and weft strands with integrated reinforcement, allowing for various patterns and shapes without the need for an anchoring structure, and incorporating 'see-through' gaps for light and air passage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Shape

If natural wicker is used for furniture, then aesthetic appeal and natural appearance are improved, but durability and resistance to water and heat deteriorate

Engineering Contradiction:

Improveaesthetic appearanceVSAvoiddurability

Core Design Contradiction:

ShapeVSReliability

Solution Approach 1:

The patent creates an artificial wicker material that copies the appearance, texture, and structural characteristics of natural wicker through extrusion processes, while using synthetic polymers that provide superior durability and resistance to environmental factors like water and heat

Inventive Principle:

Principle #26Copying

Solution Approach 2:

The invention uses composite polymer materials combining different synthetic components to achieve both the aesthetic qualities of natural wicker and enhanced mechanical properties, including resistance to moisture, heat, and structural degradation

Inventive Principle:

Principle #40Composite materials

2Shape

If natural wicker is used for furniture, then natural appearance is improved, but cost increases due to scarcity

Engineering Contradiction:

Improvenatural appearanceVSAvoidcost

Core Design Contradiction:

ShapeVSEase of manufacture

Solution Approach 1:

The patent produces artificial wicker that visually copies natural wicker through controlled extrusion and texturing processes, eliminating dependence on scarce natural resources while maintaining the desired aesthetic appearance

Inventive Principle:

Principle #26Copying

Solution Approach 2:

The invention modifies material parameters by using synthetic polymers with adjustable properties that can be tuned to match natural wicker's appearance while providing consistent supply and lower cost through industrial manufacturing processes

Inventive Principle:

Principle #35Parameter changes

3Reliability

If artificial wicker made of extruded plastic is used, then cost decreases and durability improves, but aesthetic appeal and resemblance to natural wicker deteriorate

Engineering Contradiction:

ImprovedurabilityVSAvoidaesthetic appeal

Core Design Contradiction:

ReliabilityVSShape

Solution Approach 1:

The patent applies different surface qualities and textures to different regions of the extruded material, creating localized variations that mimic the natural irregularities and visual characteristics of real wicker while maintaining the underlying durability of synthetic materials

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The invention incorporates color variations, veining patterns, and surface texturing in the extrusion process to replicate the natural appearance of wicker, transforming uniform plastic into material that visually resembles natural fibers

Inventive Principle:

Principle #32Color changes

4Shape

If natural wicker is used for furniture, then natural appearance is improved, but labor time and processing complexity increase

Engineering Contradiction:

Improvenatural appearanceVSAvoidprocessing time

Core Design Contradiction:

ShapeVSLoss of time

Solution Approach 1:

The patent performs all necessary shaping, texturing, and finishing operations during the extrusion process itself, creating ready-to-use artificial wicker strands that eliminate subsequent manual processing steps required for natural wicker preparation

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The invention replaces labor-intensive manual weaving and processing of natural wicker with automated extrusion and forming machinery that produces pre-shaped artificial wicker components ready for assembly

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 solution provides a durable, aesthetically pleasing, and cost-effective alternative to natural wicker that can withstand outdoor conditions and is suitable for various applications, including furniture, with improved mechanical properties and design flexibility.

Implementation Method 1

A panel manufactured through injection molding that mimics natural wickerwork

Methodology Applied

Scientific EffectInjection molding:

Data Source

PatentUS9820574B2Artificial panel, a method for manufacturing same and furniture articles therefrom

Publication Date: 2017.11.21 KETER PLASTIC LTD

AI summary

A molded panel resembling a natural wickerwork panel, a furniture article comprising such a panel and a method for its manufacture, the panel comprising a plurality of warp strands and a plurality of weft strands interlacing the warp strands, such that at locations where warp and weft strands intersect they form together an integrated, solid molded material location.