Multi-Layer Board Panel with Slits for Curved Surface Formation
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Solution Overview
Problem
Existing board panels for furniture and partition walls struggle to achieve curved shapes without sacrificing strength or requiring costly and labor-intensive craftsmanship, as they often rely on limited materials like foamed resin and cannot be easily removed or reconfigured.
Innovation Solution
A board panel design featuring stacked layers of hard and soft materials with strategically placed slits allows for easy curvature formation while maintaining strength and decoration, enabling economic transport, attachment, and detachment without the need for extensive craftsmanship.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If slits go through the board panel in the side direction, then curved surface formation is enabled, but the surface part becomes a divided rectangle which reduces strength
Solution Approach 1:
The board panel is divided into multiple layers (front face layer, intermediate layer, rear face layer) with slits positioned only in the front face layer. This segmentation allows the curved surface formation through slits while the intermediate and rear layers maintain structural strength and continuity.
Solution Approach 2:
The slits are localized to specific regions (front face layer only) rather than penetrating the entire board panel. This local quality approach enables curvature where needed while preserving strength in the intermediate and rear layers that remain solid and continuous.
2Shape
If foamed resin is used as board panel material, then curved surface formation is enabled, but insufficient strength is obtained when pressed from outside
Solution Approach 1:
The board panel uses a composite structure combining front face layer (with slits for curvature), intermediate layer (for strength and stability), and rear face layer (for additional strength). This composite material approach allows the front layer to form curved surfaces while the intermediate and rear layers provide the necessary compressive strength.
3Strength
If bent veneers are laminated on the board panel, then strength is improved, but much expense in time and effort and craftsmanship is required
Solution Approach 1:
The board panel is segmented into multiple functional layers where the intermediate and rear layers themselves provide strength rather than requiring additional veneer lamination. This reduces manufacturing complexity by eliminating the need for separate strengthening operations.
Solution Approach 2:
The intermediate and rear layers of the board panel serve the dual function of providing structural strength and stability while also serving as the base for curvature formation. This self-service approach eliminates the need for additional bent veneer lamination to strengthen the panel.
4Strength
If the board panel is fixed with bent veneers, then strength is improved, but the board panel cannot be removed which is uneconomical
Solution Approach 1:
The multi-layer composite structure provides inherent strength through its layered construction with the intermediate and rear layers acting as structural supports. This eliminates the need for permanent veneer fixation, allowing the board panel to be removed and reinstalled without compromising strength.
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 board panel effectively provides a curved surface while preserving strength and aesthetic appeal, facilitating versatile use in furniture and partition walls with reduced manufacturing time and cost, and enhanced durability.
Implementation Method 1
the soft material has elasticity to absorb the pressure (the pressure generated by the weight of a person, for instance, for use in a chair-seat) applied to the surface of the board panel
Implementation Method 2
the front face layer is a layer of a hard material in which slits are provided... A curvature can be formed easily in the horizontal direction of the rectangle
Data Source
AI summary
The present invention is transportable economically in a flat state, and easy to attach and detach, and can provide a curved surface simply while maintaining decoration and strength without craftsmanship. Slits are provided on a rectangular board panel comprising two or more layers of a hard material and a soft material. Two or more layers comprising a hard material and a soft material are laminated on a rectangular board panel, and slits having a length of ½ to ¾ of the vertical side are provided thereto. The use of slits makes formation of curved surfaces easy. Since there is no need to reinforce the outside to maintain the strength thereof, the board panel can be removed easily. Even if in external pressure is applied to the board panel, the flexibility of the hard material divided by the slits and the elastic characteristic of the soft material cause the pressure to be dispersed and absorbed.