Inner support panel and applications
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Solution Overview
Problem
Conventional plastic panel boards face issues with insufficient structural strength, leading to weight limitations and potential collapse, and existing reinforcement methods increase costs and weight, while also affecting manufacturing processes with uneven heat dissipation and shrinkage.
Innovation Solution
A triple-layer blow-molded inner support panel with an outer and intermediate layer made of high-density polyethylene and an inner layer of metallocene polyethylene, featuring recessed portions that form touching support members with reinforcing ribs, providing enhanced structural strength and impact resistance without excessive weight or manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If reinforcing ribs are added to enhance panel strength, then structural strength is improved, but overall weight increases
Solution Approach 1:
The panel is divided into multiple layers (first panel portion and second panel portion) with support members strategically positioned within the hollow structure, distributing the load-bearing function across segmented elements rather than using continuous heavy reinforcement
Solution Approach 2:
Support members are placed at specific locations within the hollow structure where they provide maximum structural benefit, creating local reinforcement zones rather than uniformly increasing thickness or adding ribs across the entire panel surface
2Strength
If reinforcing ribs are added to enhance panel strength, then structural strength is improved, but device complexity increases
Solution Approach 1:
The support members are integrated directly into the hollow structure during the blow-molding process, merging the reinforcement function with the panel body structure rather than adding separate components that would increase assembly complexity
Solution Approach 2:
The hollow structure itself serves dual purposes: providing the panel's basic form and simultaneously housing the support members that reinforce structural strength, making the structure self-sufficient without requiring additional external reinforcement elements
3Strength
If material composition is optimized to enhance strength, then structural strength is improved, but manufacturing cost increases
Solution Approach 1:
The panel thickness and support member dimensions are optimized within the blow-molding process parameters, allowing strength enhancement through geometric parameter adjustment rather than requiring expensive high-strength materials
Solution Approach 2:
The panel uses a composite structure combining the hollow space with solid support members, creating a lightweight composite system that achieves high strength-to-weight ratio without requiring expensive reinforcement materials
4Strength
If panel thickness is increased to enhance strength, then structural strength is improved, but heat dissipation during manufacturing becomes uneven
Solution Approach 1:
The panel is structured as multiple thinner layers (first and second panel portions) separated by hollow space, with support members providing localized thickness enhancement only where structurally necessary, maintaining relatively uniform wall thickness for even heat dissipation during blow-molding
Solution Approach 2:
Instead of increasing thickness in the vertical dimension throughout the panel, the invention uses the internal hollow space to house support members, providing structural enhancement in the horizontal dimension without compromising manufacturing heat dissipation
Data Source
AI summary
An inner support panel includes a first partial panel, a second partial panel, a first layer, a second layer a first panel portion, a second panel portion, a first layer, a second layer, and at least one support structure. The first layer is stacked on the second layer. The first partial panel includes one or two combinations consisting of at least part of the first layer and at least part of the second layer. The second partial panel includes one or two combinations consisting of at least the other part of the first layer and at least the other part of the second layer. The first partial panel and the second partial panel are connected to each other and form a hollow structure by defining a cavity. At least part of the second partial panel extends towards the cavity to form the support structure. The first partial panel can be supported by the support structure.