Lightweight Building Panel Support Structures Without Post-Milling
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Solution Overview
Problem
Existing methods for producing lightweight panels with support structures are labor-intensive and costly, and the support structures often fail to withstand high pressing pressures required for applying synthetic resin-based decorative coatings.
Innovation Solution
A method involving a press mold with recesses for forming support structures during the pressing process, where particles are introduced into these recesses and distributed using air currents or vibrations, allowing precise control of support structure height and enabling simultaneous production with a decorative coating application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If support structures are pressed into the material mat during pressing, then support structures are formed, but significant inaccuracies in support structure height occur
Solution Approach 1:
The press mold is pre-equipped with recesses at the desired depth and position before the pressing process. These recesses serve as predetermined locations where support structures will form, ensuring accurate height and position control from the outset rather than attempting to press structures into an already-formed mat.
Solution Approach 2:
The pressing process is segmented into two distinct phases: first, particles are introduced into the recesses of the press mold to form support structures; second, the remaining material mat is pressed. This segmentation allows each phase to be optimized independently, with the support structure formation occurring in predetermined locations without interference from the pressing pressure.
2Manufacturing precision
If subsequent milling is used to control support structure height, then precise control is achieved, but production becomes very labor-intensive and costly
Solution Approach 1:
The press mold recesses are pre-configured with the exact depth and dimensions needed for the support structures before pressing begins. This preliminary preparation eliminates the need for subsequent milling operations, as the support structures achieve their final precise dimensions directly during the pressing process.
Solution Approach 2:
The unnecessary milling step is completely removed from the production process. By integrating the height control function directly into the press mold design, the patent extracts and eliminates the separate post-processing operation that would otherwise be required.
3Ease of manufacture
If particles are simply arranged on the press mold, then production is simple, but uniform distribution of particles in recesses is difficult to achieve
Solution Approach 1:
The press mold is subjected to mechanical vibration during the particle introduction phase. This vibration causes the particles to settle uniformly into the recesses, ensuring consistent filling and distribution without requiring complex manual arrangement processes.
Solution Approach 2:
Air currents are used to transport and distribute particles into the recesses of the press mold. The pneumatic system ensures uniform particle distribution by controlling the flow and deposition of particles in the recesses, achieving consistent filling across all support structure locations.
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 produces lightweight panels with uniform and stable support structures that can withstand high pressing pressures, reducing production effort and costs while ensuring secure bonding with material sheets.
Implementation Method 1
whereby, after the application of the particles, they are additionally wiped, swept in or brushed in and/or transported into the recesses by means of air currents
Implementation Method 2
pressing the mat into the partial plate with support structures on a plate surface in a press
Data Source
Figure 1
Figure 2a~3
Figure 4a~4c
AI summary
The invention relates to a method for producing a lightweight building panel, in which, in order to produce a pressing material mat that can be compressed to form a partial panel: organic particles to which glue has been applied are arranged on a first press mould; the pressing material mat is pressed in a press to form the partial panel having supporting structures on one panel side; and the supporting structures are connected to a material panel. In order to provide a method for producing lightweight building panels, by means of which method partial panels having a supporting structure can be produced simply and economically, according to the invention the first press mould has depressions for producing supporting structures on one surface of the partial panel and, during production of the pressing material mat, some of the particles are introduced into the depressions.