Molded Plastic Benchtop Panels Grid Structure
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Solution Overview
Problem
Existing prefabricated molded plastic benchtop panels struggle to be lightweight, high-strength, and easily modifiable in standard dimensions while also being easily mountable and connectable to frames or substructures.
Innovation Solution
A molded plastic benchtop panel with a rectangular grid-like structure that can be cut to various dimensions, featuring spaced mounting flanges for easy attachment to frames and a connector system for rapid assembly of panels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If prefabricated molded plastic panels are used, then manufacturing is simplified, but strength and modifiability are compromised
Solution Approach 1:
The panel is divided into a grid pattern with multiple openings that segment the solid plastic into reinforced zones. This segmentation allows the panel to maintain strength while being lightweight and modifiable, as the grid structure distributes loads across multiple reinforcement points rather than requiring continuous solid material.
Solution Approach 2:
The panel combines molded plastic with a grid reinforcement structure to create a composite construction. This composite approach allows the plastic to provide corrosion resistance and basic structural form, while the grid pattern provides additional strength and rigidity, resolving the contradiction between ease of manufacture and strength.
2Adaptability or versatility
If standard dimensions are used, then inventory and installation are simplified, but adaptability to custom sizes is reduced
Solution Approach 1:
The grid pattern divides the panel into standardized modular sections that can be independently adjusted. This segmentation allows custom sizes to be achieved by combining or removing grid sections while maintaining the same basic panel construction, thus providing adaptability without significantly increasing complexity.
Solution Approach 2:
The standardized grid pattern serves multiple functions: it provides structural reinforcement, defines modular sections for custom sizing, and maintains consistent manufacturing processes. This universality allows a single panel design to accommodate various dimensions and applications, resolving the contradiction between adaptability and complexity.
3Ease of operation
If mounting flanges are added, then ease of attachment to frames is improved, but panel complexity increases
Solution Approach 1:
The mounting flanges are merged with the grid pattern structure rather than being separate additions. This integration allows the flanges to be formed as part of the grid construction process, providing ease of attachment to frames while minimizing the increase in overall panel complexity through combined structural and mounting functions.
4Weight of stationary object
If material is minimized, then weight and cost are reduced, but structural strength may be compromised
Solution Approach 1:
The panel uses composite construction combining molded plastic with grid reinforcement patterns to achieve optimal strength-to-weight ratio. This composite approach allows material minimization by replacing solid plastic with strategically placed grid structures that provide necessary strength while reducing overall material usage and weight.
Solution Approach 2:
The grid pattern segments the panel structure into reinforced zones that provide maximum strength with minimum material. By concentrating material only where the grid pattern indicates rather than using uniform solid construction, the panel achieves required strength while minimizing weight and material cost.
Data Source
AI summary
Benchtop panels are formed with spaced apart longitudinal edge webs and intermediate webs and spaced apart transverse edge webs and intermediate webs forming a grid with parallel top and bottom surfaces. At least one pair of longitudinal and transverse intermediate webs are closely spaced to allow subdividing the panel into plural panels by severing portions of a panel at a point between the closely spaced webs. Longitudinal bottom surface flanges provide for ease of mounting panels on a frame or table at spaced apart frame members. A connector with spaced apart legs and a connecting tab may be inserted in openings formed in gussets of adjacent panels to secure panels to each other.